Abstract:
An improved tunnel washer apparatus ( 20 ) is disclosed that includes a “ratio metric” water reuse system that features four water loops. The water loops include fresh water ( 24 ), reuse water ( 51 ), rinse water ( 49 ), and treated water ( 50 ). The tunnel washer ( 20 ) has five stages that include wet out ( 13 ), first wash zone ( 14 ), second wash zone ( 15 ), main rinse zone ( 16 ), and fine rinse/finishing zone ( 17 ). The water loops are designed to minimize the consumption of fresh water by blending the appropriate quantity of the four types of water. The blending formulation may vary based on the type of goods (for example linen) in the tunnel stage and the dynamic quality of each type of water.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    Priority is hereby claimed to U.S. Provisional Patent Application No. 60/313,101, filed Aug. 17, 2001.  
         [0002]    U.S. Provisional Patent Application No. 60/313,101, filed Aug. 17, 2001, is incorporated herein by reference. 
     
    
     
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
         [0003]    Not applicable  
         REFERENCE TO A “MICROFICHE APPENDIX” 
         [0004]    Not applicable  
         BACKGROUND OF THE INVENTION  
         [0005]    1. Field of the Invention  
           [0006]    The present invention relates to continuous batch-type washing machines. More particularly, the present invention relates to an improvement in a continuous batch-type washing machine that features an improved multi-loop water reuse arrangement. Even more particularly, the present invention relates to an improved continuous batch-type washing machine apparatus wherein there are three water “loops” in addition to a fresh water loop. The additional “loops” include reuse water, rinse water, and treated water.  
           [0007]    The system of the present invention provides significant energy and water conservation thus reducing operating costs.  
           [0008]    2. General Background of the Invention  
           [0009]    In machines that are known in the industry as “tunnel washers”, each of a succession of drums or baskets is mounted for rotation within a housing that includes a bath of liquor during each washing cycle. Each drum is contained within an individual compartment or cell of a succession of cells forming the tunnel. Goods to be cleaned (such as cloth goods) are transferred sequentially from a drum into the next successive drum. Intermediate washing cycles are provided for causing liquor to circulate through each drum compartment and maintaining a desired level of liquor making up the bath during each washing cycle. Thus, successive batches of cloth goods may be fed via a hopper into the leading drum at the front end and removed from the trailing drum at the rear end of the passage and through intermediate drums.  
           [0010]    Depending on the design and arrangement of the individual machines, water may be circulated through one or more drum compartments at the front portion of the machine for pre-wash and soap detergents and pH conditioning chemicals may be added to the water circulated through several of the following drum compartments in the main wash stage of the machine. The goods may then be bleached, unused, or conditioned rinsed with water circulated through one or more succeeding drum compartments. Water is circulated through the final drum compartments. In some cases, liquor may not pass entirely through the machine from one end to the other. For example, certain of the different types of liquor may be prevented from co-mingling.  
           [0011]    Various patents have been issued for continuous tunnel washer batch-type washing machines and methods for operating them. The assignee of the present invention, Pellerin Milnor Corporation of Kenner, La. is the assignee of several such “tunnel washer” patents that are listed in Table 1 below:  
                             TABLE 1                           PELLERIN MILNOR PATENTS            PATENT #   ISSUE DATE   TITLE               4,236,393   02 Dec. 1980   Continuous Tunnel Batch Washer       4,363,090   07 Dec. 1982   Process Control method and               Apparatus       4,485,509   04 Dec. 1984   Continuous Batch Type Washing               Machine and Method for Operating               Same       5,211,039   18 May 1993   Continuous Batch Type Washing               Machine       5,454,237   03 Oct. 1995   Continuous Batch Type Washing               Machine                  
 
           [0012]    Other patents have issued that relate generally to the concept of a laundry machine or tunnel type commercial duty washing machine:  
                             TABLE 2                           WASHER PATENTS            PATENT #   ISSUE DATE   TITLE               3,103,802   17 Sept. 1963   Washing Machine       3,336,768   22 Aug. 1967   Washing Machines       3,406,543   22 Oct. 1968   Washing Machines, Notably Laundry               Machines       3,509,744   05 May 1970   Washing Machines, and Especially               Laundry Machines       3,550,406   29 Dec. 1970   Machine for Washing Laundry       3,693,639   26 Sept. 1972   Apparatus for Treating Articles               With Liquid Treatment Media       3,995,458   07 Dec. 1976   Laundry Machine       4,020,659   03 May 1977   Tunnel-Type Commercial-Duty               Washing Machine       4,109,493   29 Aug. 1978   Drum-Type Machine for the               Treatment of Textile Material                  
 
           [0013]    Tunnel washers are typically very large machines that are employed in commercial service. Users can include hotels and hospitals, for example.  
           [0014]    Tunnel washers consume a large amount of water on a yearly basis. They also require a substantial amount of energy for heating. On a yearly basis, water and energy costs can be hundreds of thousands of dollars for a large installation.  
         BRIEF SUMMARY OF THE INVENTION  
         [0015]    The present invention provides an improved tunnel washer apparatus that can be energy and water saving. The system of the present invention can feature three water loops in addition to the fresh water loop. The additional loops include reuse water, rinse water, and treated water.  
           [0016]    The improved tunnel washer of the present invention provides preferably five stages or zones: wet out, first wash zone, second wash zone, main rinse, and fine rinse/finishing.  
           [0017]    The water loops of the present invention help minimize the consumption of fresh water by blending a selected, appropriate quantity of the four types of water that are provided by the four loops. The blending formulation may be selected based upon the type of linen in the various tunnel stages and the dynamic quality of each type of water in the various loops.  
           [0018]    The present invention thus provides an improved ratio metric flow arrangement and tunnel washer system.  
           [0019]    Process water from a wash zone is treated in line and recirculated in both wash zones of the apparatus. The primary flow in the second wash zone is recirculated. The only makeup water can be used to replace the rejects from the filtration components.  
           [0020]    The water treatment uses an oxidizer to breakdown organic material and a centrifugal separation unit to remove suspended solids.  
           [0021]    By directly reusing this water, the water remains at the programed temperature, thereby dramatically reducing the heating energy required. Normally this water is sent to a sewer or to a centralized water treatment system, losing energy and adding significant cost to the installed system.  
           [0022]    Conventional attempts to use central water treated water have not been successful because of the temperature and chemical incompatibility.  
           [0023]    In the second wash zone, the dilution rate is increased over conventional designs because of the recirculated process liquor flowing at up to 300% of the conventional flow rate.  
           [0024]    The purpose of increased flow rate is to improve the washing effect by increasing the dilution effect, as illustrated in the following Table 3.  
                                                                                                                           TABLE 3                                               Finish of           % of Main Rinse Water   Main Rinse   Fine Rinse                Fresh   Total   Fresh   Total   Fresh   Total   Fresh   Total   Fresh   Total           Water   Water   Water   Water   Water   Water   Water   Water   Water   Water                        Conven-   10   50   65   65   65   65   100   100   5   5       tional       Ration   10   50   0   46-   10   300   40-   40-   0   0-                       65           80   80       20                  
 
           [0025]    Sensors (e.g. turbidity sensors) are preferably used to measure the quality of the wash water zone. Upon reaching a selected limit, fresh water is increased to dilute the dissolved solids level. This water is then treated to improve its quality. Ozone, alone or in combination with other oxidizers, can be used directly in the pumped treated water stream to break down organic compounds. Alternative and/or replacement oxidizers can include chlorine dioxide or ultraviolet treatment. These can be used in place of or in addition to ozone. It is optional to filter this treated flow using an inline filter to further clarify the treated water. A cyclone separator or like filter can be used to remove suspended solids which can be reduced to preferably less than between about 50 to 500 parts per million, preferably about 100 parts per million.  
           [0026]    The last “module” or cell is configured to primarily use water from the main rinse section as an overflow fine rinse. This water is recovered in a tank and used as reuse water for part of the flushing water in the wet out (inlet) zone.  
           [0027]    For operating the present invention, fresh water is introduced into the last cell or module of the main rinse zone after start-up stabilization. The water counter flows to the first module in the rinse zone. The water is collected in a tank. The rate of flow in the rinse zone is selected based on the type of goods that are being washed. The rate of flow can be varied depending on the soil levels in different batches of goods. For example, when heavy soil follows light soil, the rinse zone water may be increased to address higher detergent and alkali levels. Additionally, the level of dissolved solids is measured in the tank. If the level exceeds a selected, programmed limit, the fresh water flow rate is increased. A computer can be used with the sensors to monitor water quality. A plurality of modulating valves can be computer controlled to automatically maintain water quality levels for water that is added to the apparatus at the various cells or at stages that include multiple cells.  
           [0028]    The first wash zone reuses the highest percentage of the rinse water when compared to the flow into the second wash zone and the final rinse zone. The first wash zone can be programmed to blend fresh water if required.  
           [0029]    The second wash zone principally reuses its own treated water, blended with approximately 20% rinse water and 10% fresh water. These values can be programmable, generally about 0 to about 65% rinse and about 0 to about 65% fresh water.  
           [0030]    The present invention thus provides an improved continuous tunnel batch washer apparatus that includes an elongated outer housing having opposed ends, an inlet at one of said ends and an outlet at the other of said ends, the housing having a water containing portion for washing goods.  
           [0031]    A plurality of lateral walls divides at least a portion of the housing into a plurality of cells. The housing contains a plurality of drums, preferably one drum for each cell. Each of the drums is rotatably supported within the water containing portion of the frame. Each drum has an inlet for enabling goods to be washed to enter the drum and a drum outlet for enabling the goods to exit the drum.  
           [0032]    A fresh water header is provided for supplying water to the water containing portion of the housing.  
           [0033]    A rinse water flow line receives water that has been discharged from the water containing portion of the housing, for reuse.  
           [0034]    A treated water flow line receives water that has been discharged from the water containing portion of the housing, for reuse.  
           [0035]    Water treatment is provided for removing solid waste material from water that has been discharged from the water containing portion of the housing. Such treated water is transmitted to the treated water flow line.  
           [0036]    Water flowing in the treated water flow line is supplied to the second wash zone. Water flowing in the rinse zone is supplied to the first and/or second wash zones, and optionally the fine rinse and finish zone. Water flowing in the reuse flow line is used in the “wet out” or intake zone. The fresh water header can optionally supply water to the wet out (intake) zone, the first and second wash zones, the main rinse zone and the fine rinse and finish zone. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0037]    For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:  
         [0038]    [0038]FIG. 1 is a schematic flow diagram of the preferred embodiment of the apparatus of the present invention.  
         [0039]    [0039]FIG. 2 includes some preferred ranges for water. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0040]    In FIG. 1, the tunnel batch washer apparatus of the present invention is designated generally by the numeral  20 . Tunnel batch washer  20  has an inlet end portion  18  (e.g. hopper) and an outlet end portion  19 . A housing  20 A is defined by a plurality of cells  1 - 12 . There can be more cells. The maximum number is preferably (but not limited to)  32 . The cells  1 - 12  can be defined by lateral dividing walls of the housing  20 A. The housing  20 A provides a water containing portion. One or more of the cells  1 - 12  can provide drums that are rotatable. Chutes on each drum transfer goods from one drum to the next drum. Thus, each drum has an inlet and an outlet so that goods to be washed can enter and exit each drum.  
         [0041]    One or more of the above listed Pellerin Milnor patents in Table 1 discloses the general concept of a tunnel batch washer that includes a housing, a water containing portion, a plurality of cells, drums contained within the cells, and chutes associated with each of the drums for transferring clothes or other goods to be cleaned from one drum to the next drum. Each of the above listed patents contained in the Tables 1 and 2 is hereby incorporated herein by reference.  
         [0042]    The housing  20 A has five (5) zones or stages: wet out first wash, second wash, main rinse, and fine rinse/finish. Next to inlet  18  there is provided a wet out zone  13 . The wet out zone  13  provides a hopper or chute that allows clothing, linens, cloth goods or other articles to be washed to be added to the housing  20 A. Thus cell number  1  defines the “wet out” or inlet zone  13 . Cells  2 ,  3 ,  4  and  5  define a first wash zone  14 . Cells  6 ,  7 ,  8  and  9  define a second wash zone  15 . A main rinse zone  16  is defined by cells  10  and  11 . A fine rinse and finish zone  17  is defined by the cell  12 .  
         [0043]    During operation, the goods to be cleaned move in the direction of arrow  21 , entering the housing  20 A at inlet  18  and exiting the housing  20 A at outlet  19 . In general, water flow in housing  20 A is in the opposite direction of arrow  21 . The goods that exit outlet  19  can be transported to a press, the details of which are known in the art and therefore not disclosed herein. Pressed water from the press or other extracting device is contained in a tank  22 . The arrow  23  schematically illustrates the transfer of goods from housing  20 A to a known press so that water can be removed from the linens or other washed goods and collected at press water return tank  22 .  
         [0044]    The apparatus  20  of the present invention provides four different main headers or flow lines. These include fresh water header  24 , rinse water flow line  49 , treated water flow line  50  and reuse water flow line  51 . The various headers and flow lines  24 ,  49 ,  50 ,  51  supply water to different stages or zones of the housing  20 A. For example, treated water flowing in the flow line  50  is reused in the second wash zone  15 . Rinse water flowing in the flow line  49  is optionally used in the first wash zone  14 , second wash zone  15 , main rinse zone  16 , and fine rinse and finish zone  17 . Reuse water flowing in line  51  is the water collected from the press water return tank  22 , main rinse  16  and fine rinse and finish  17 . This reuse water flows in line  51  to the wet out or inlet stage  13 . Fresh water is optionally supplied to the wet out zone  13  using fresh water header  24 , first and second wash zones  14 ,  15 , main rinse zone  16 , and fine rinse and finish zone  17 .  
         [0045]    A plurality of modulating valves  25 - 34  are provided for enabling selected control of the percentage of water from the various headers or flow lines  24 ,  49 ,  50 ,  51  that are added to selected stages. For example, at the wet out stage  13 , reuse water and fresh water are supplied through the respective headers  51  and  24 . Modulating valve  25  controls the flow of reuse water in line  51 . Valve  26  controls fresh water in line  24  that is added to the wet out zone  13 . Modulating valve  27  controls the flow of fresh water in header  24  while valve  28  controls rinse water in flow line  49  that is to be added via lines  24 ,  49  to the first wash zone  14 . Modulating valves  29 ,  30  and  31  control the flow of water that is added to the second wash zone  15 . The valve  29  controls the flow of fresh water from header  24  that is added to the second wash zone  15 . The valve  30  controls the flow of rinse water from flow line  49  that is added to the second wash zone and the valve  30  controls the flow of treated water from flow line  50  that is added to the second wash zone. A computer can be used to control the valves  25 - 34 , and pumps that drive flow in the lines  24 ,  49 ,  50  and  51 . Modulating valves  25 - 34  can be models commercially available.  
         [0046]    The main rinse zone  16  can be supplied by fresh water received from header  24  as controlled by modulating valve  32 . The fine rinse and finish zone  17  is supplied with a combination of fresh water from header  24  as controlled by valve  33  and rinse water supplied by flow line  49  as controlled by valve  34 .  
         [0047]    A tank  35  is provided for receiving water as it exits housing  28  from main rinse zone  16  and fine rinse and finish zone  17 . The tank  35  has tank sections  36 ,  37 . A tank  38  is provided for receiving flow from the second wash zone via second wash zone flow line  53 . Flow line  54  is provided for transferring water from the main rinse  16  and to tank  35 . Flowline  55  is provided for transferring water from the fine rinse and finish  17  stages to tank  35 . Downstream of second wash zone  15 , flow line  53  has a branch portion that includes two valves  46  and  47 . These valves  46  and  47  control the flow of water to tank  38 , or to be discharged for example, to a sewer. The tank  38  communicates with flow line  60  for supplying water through valve  48  to pump  42 . The water flowing in line  60  is water that is to be treated and then reused. Treatment can include centrifugal separator combination cleaner  43 , ozone injection  44 , carbon filtration, ultraviolet treatment, and/or reverse osmosis filtration. Flow line  61  schematically indicates the discharge of reject solids from separator  43  to a suitable discharge site.  
         [0048]    Tank  35  also receives the press water return from tank  22  via flow line  56 . The press water return flow line  56  receives flow from pump  39  and pump suction line  57 . Water that is received in tank  35  can be tested for quality using a sensor such as turbidity sensor  45 . Water quality can also be tested for total suspended solids being preferably less than  100  parts per million. Suction line  58  receives flow from tank  35  and communicates with pump  40  for pumping water in flow line  49 . Some of the water in tank  35  can also be received by suction line  59  for transfer to pump  41  to be pumped as reuse water in line  51  for transfer to the wet out zone  13 .  
         [0049]    A turbidity sensor  45  can determine the quality of water in tanks  35  and  38 . Water quality can also be tested for total suspended solids being preferably less than  100  parts per million. A determination is made of whether to transfer that water to the rinse flow line  49  or to the reuse flow line  51 . If the turbidity sensor  45  at tank  35  indicates that the water in tank  35  is too dirty for use as rinse water, the pump  41  will be activated and the pump  40  will be deactivated so that only reuse flow line  51  receives water from tank  35 . If the turbidity sensor  45  indicates that the water quality in tank  35  is good enough, pump  41  is deactivated and pump  40  is activated so that the water contained in tank  35  is used in flow line  49  for rinse water.  
         [0050]    Flow lines are provided for supplying fluid to the various zones  13 - 17  after the modulating valves have controlled the percentage of water that flows from various of the different headers or flow lines. For example, the first wash zone flow line  52  receives flow through valves  27  and  28  from either fresh water header  24  or rinse water flow line  49 . The second wash zone flow line  53  receives water that passes through valves  29 ,  30  and  31 . The valve  29  controls the flow of fresh water, the valve  30  controls the flow of rinse water and the valve  31  controls the flow of treated water. Main rinse flow line  54  receives water directly from header  24  as controlled by valve  32 . Fine rinse flow line  55  receives water from valves  33 ,  34  that includes a selective amount of fresh water from header  34  and rinse water from flow line  49 .  
         [0051]    Computer controls can be programmed to set the ratio of flow for each water loop into each of the 5 zones. These formulas are assigned to a wash classification. When different goods are in adjacent modules, the computer controls can set the water flow and ratios to the program that uses the most fresh water. Additionally, the computer controls can be programmed according to chemical and water loop compatibility setting the formula to the safest chemical formula highest fresh water settings.  
         [0052]    Water that exits the wet out zone  13  via flow line  62  is typically waste water that is discarded to a suitable discharge site. Water exiting first wash zone  52  can either be discarded to a suitable discharge site or used as reuse water and added via flow line  63  to reuse flow line  51 .  
         [0053]    [0053]FIG. 2 includes some preferred ranges for water for reusing water in various zones. The ranges are about zero to about the amount shown.  
       Parts List  
       [0054]    The following is a list of suitable parts and materials for the various elements of the preferred embodiment of the present invention.  
       Parts List  
       [0055]    Part No. Description  
         [0056]    [0056] 1  cell  
         [0057]    [0057] 2  cell  
         [0058]    [0058] 3  cell  
         [0059]    [0059] 4  cell  
         [0060]    [0060] 5  cell  
         [0061]    [0061] 6  cell  
         [0062]    [0062] 7  cell  
         [0063]    [0063] 8  cell  
         [0064]    [0064] 9  cell  
         [0065]    [0065] 10  cell  
         [0066]    [0066] 11  cell  
         [0067]    [0067] 12  cell  
         [0068]    [0068] 13  wet out zone  
         [0069]    [0069] 14  first wash zone  
         [0070]    [0070] 15  second wash zone  
         [0071]    [0071] 16  main rinse zone  
         [0072]    [0072] 17  fine rinse and finish zone  
         [0073]    [0073] 18  inlet  
         [0074]    [0074] 19  outlet  
         [0075]    [0075] 20  tunnel batch washer  
         [0076]    [0076] 20 A housing  
         [0077]    [0077] 21  arrow  
         [0078]    [0078] 22  press water return tank  
         [0079]    [0079] 23  arrow  
         [0080]    [0080] 24  fresh water header  
         [0081]    [0081] 25  modulating valve  
         [0082]    [0082] 26  modulating valve  
         [0083]    [0083] 27  modulating valve  
         [0084]    [0084] 28  modulating valve  
         [0085]    [0085] 29  modulating valve  
         [0086]    [0086] 30  modulating valve  
         [0087]    [0087] 31  modulating valve  
         [0088]    [0088] 32  modulating valve  
         [0089]    [0089] 33  modulating valve  
         [0090]    [0090] 34  modulating valve tank  
         [0091]    [0091] 36  tank section  
         [0092]    [0092] 37  tank section  
         [0093]    [0093] 38  tank  
         [0094]    [0094] 39  pump  
         [0095]    [0095] 40  pump  
         [0096]    [0096] 41  pump  
         [0097]    [0097] 42  pump  
         [0098]    [0098] 43  centrifugal separator  
         [0099]    [0099] 44  ozone injector  
         [0100]    [0100] 45  turbidity sensor  
         [0101]    [0101] 46  valve  
         [0102]    [0102] 47  valve  
         [0103]    [0103] 48  valve  
         [0104]    [0104] 49  rinse water flow line  
         [0105]    [0105] 50  treated water flow line  
         [0106]    [0106] 51  reuse water flow line  
         [0107]    [0107] 52  first wash zone flow line  
         [0108]    [0108] 53  second wash zone flow line  
         [0109]    [0109] 54  main rinse flow line  
         [0110]    [0110] 55  fine rinse flow line  
         [0111]    [0111] 56  press water return flow line  
         [0112]    [0112] 57  pump suction line  
         [0113]    [0113] 58  pump suction line  
         [0114]    [0114] 59  pump suction line  
         [0115]    [0115] 60  pump suction line  
         [0116]    [0116] 61  reject solids flow line  
         [0117]    [0117] 62  reject flow line  
         [0118]    [0118] 63  reuse flow line  
         [0119]    The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.