Patent Abstract:
The multi-stage coil washer is a system for removing oil and other contaminants from flat metal feed stock for further processing. The system utilizes wash, rinse and dry off stages to remove all of the contaminants and leave a small amount of oil to prevent flash rusting, in the case of a metal feed stock that rusts, and allow for storage. The wash and rinse system use a series of rolls in cartridges, individually motor driven, to clean the metal feed stock comprising of a combination of hard chrome, abrasive embedded non-woven and fibrous rolls. Each cartridge containing a top and bottom roll can be removed. Separate heated wash and rinse fluids are used wash and rinse fluid are separately contained in individual tanks which contain multiple cleaning apparatuses. Each tank cleans the water using micron filters, bacteria filters, magnets, oil separators and centrifuges. The centrifuges remove oil from the water and recycle the cleaned water back into the tank. A mist containment unit prevents mist and steam from escaping in the assembly and the mist collector recycles the recaptured water back into the rinse water tank. The multi-stage metal feed stock washer is an environmentally friendly system designed to continually recycle its wash and rinse water with little waste.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    N/A 
       STATEMENTS REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    N/A 
       REFERENCE TO A MICROFICHE APPENDIX 
       [0003]    N/A 
       BACKGROUND OF THE INVENTION 
       [0004]    1. Field of the Invention 
         [0005]    This invention generally relates to a processed metal cleaning or wash system and method for cleaning and drying metal. The cleaning is done after the metal has been un-coiled, and straightened in the case of coil of flat metal sheeting. Processed steel or other flat metal sheet typically contain lubrication oil that is used in the processing and bending of the flat sheet metal and must be removed prior to application of paint. If the flat sheet metal has too much oil remaining the paint will not adhere, however if no oil remains on the flat sheet metal then it may rust in the time period between cleaning and paint application. In the case of steel it is desirable to remove a selected amount of the coating so that the steel does not incur flash rusting and can still be painted. 
         [0006]    This invention particularly relates to a processed flat sheet metal wash station and rinse station having multiple interchangeable cartridges that are selectively mounted within the coil wash or rinse station. The rolls; chrome, fibrous or abrasive embedded non-woven within each cartridge collaborate to remove oil, dirt and grime and provide clean and dry metal for the next stage in the process. A unique solution monitoring and cleaning system adds to the system effectiveness. Utilization of easily accessible ambient high speed blow-off knives, mist collectors and a strategically located heated blow-off are important ingredients in the systems overall effectiveness. A multi stage filtration system is an integral part of the overall system design. 
         [0007]    2. Description of the Related Art 
         [0008]    Some known processed flat sheet metal wash systems include a roller system and an integral tank located below the roller system. The systems utilize upper and lower rolls with the upper rolls mounted directly above the lower rolls. Some current systems utilize three or four upper rolls and three or four lower rolls. There exists in known systems entrance rolls, center rolls and exit rolls. Typically the said systems have a pre-defined gap between the upper and lower rolls. The said systems wash and rinse the un-coiled metal within the same housing, incorporate a hot air blow-off and have mist collection. The said entry and exit rolls are typically a smaller diameter than the center rolls. Each set of center rolls has a combination of a flat sheet metal roll and a squeegee roll on either top or bottom. The said coil washers may have roll lift cylinders operating at a predetermined pressure located above each set of rolls that raise the rolls for maintenance or lower them and apply pressure to the un-coiled metal. The said coil washers have an inlet on one side and an outlet on the other. Between the entrance and exit on either side of the center rolls is a fixed manifold spray system. The spray system may have a plurality of nozzles that deliver the solution used to wash or rinse the un-coiled metal passing through the system. A heated blow-off may be mounted to the exit side of the washer. Both the upper rollers and the lower rollers may be driven and may be operated by a complex chain or belt drive system. An example of prior art includes U.S. Pat. No. 6,814,089 B1. 
         [0009]    Known wash systems have some disadvantages. First, some known processed flat sheet metal wash systems (commonly known as coil washers) have six to eight rolls and or brushes all mounted in a single housing. This feature forces coil washer disassembly for maintenance or replacement of the rolls significantly increasing downtime. In addition combining the wash and rinse in a single housing may allow for cross contamination of dirty and clean solution. Moreover the combination of wash and rinse in the same housing may reduce cleaning effectiveness versus having a dedicated wash station. Wash and rinse solution monitoring may be ineffective or not done at all. Wash and rinse solutions used may not be environmentally friendly, may be expensive to use and expensive to dispose of Accessibility to the manifolds may be limited and difficult because they may be mounted directly to the washer housing. The mist collection is virtually ineffective because of air restriction and location. Chain or belt driven rolls have been found in this application to require more maintenance, are noisy and difficult to disassemble when routine maintenance is required. Rolls and brushes are driven with the same drive but wear at different rates; this speed difference stresses and marks the metal traveling through the coil washer. In addition a known flat sheet metal processing washer having many of the less desirable qualities listed above utilizes a combination of rolls and brushes for the purpose of removing scale and inhibiting oxidation. Some other systems utilize volatile organic compounds or aqueous-based detergents that result in contaminated water which must be further processed or disposed of Generally systems that use volatile organic compounds or detergents are not very recyclable in that certain components cannot be reused. 
         [0010]    Accordingly the need exists for a self monitoring flat sheet metal processing wash system that improves cleaning using hot water and no chemicals, removes oil and impurities presenting them for recycling, protects the internal plant environment by removing the all fumes and particulate from the air, permits quick accessibility and disassembly of internal components, reduces downtime, and is easily maintained. 
       BRIEF SUMMARY OF THE INVENTION 
       [0011]    The multi-stage metal washer is an environmentally friendly system and method designed to utilize hot water to remove coatings from uncoiled processed metal feed stock such as steel, aluminum and other sheet metal. Coatings typically include oil or some other corrosion preventative and other debris that can accumulate on processed metal stock. The oil is then extricated from water through high speed centrifuges and recycled, leaving the water approximately 99.0% oil-contamination free. For steel it is often desirable to remove all of the contaminants and leave a small amount of oil to prevent flash rusting, in the case of a metal feed stock that rusts, and allow for storage. The water is also recycled in the process, beginning as reverse osmosis treated water entering the rinse tank and supplying the wash tank. It is practically a closed water system in which the only water leaving the system is through evaporation, further protecting the environment and preventing waste from contaminating water sources. The washed and rinsed metal feedstock maintains a predetermined amount of oil on it which allows for it to be stored for a short period of time before rusting, in the case of steel, but does not contain enough oil to prevent further processing of the metal such as forming and applying paint. 
         [0012]    Processed metal feed stock contains oil on its surface due to forming and other processing and is washed through a system comprising a wash stage, rinse stage, and heated dry off stage. Initially, the uncoiled processed metal feed stock enters a set of air knives and proceeds to the wash system that is comprised of cartridges each with two rollers stacked on top of each other made of either hard chrome, fibrous or abrasive material. The system includes spray headers that spray heated water, via wash tank, at a pre-determined pressure on both the upper and lower sides of the flat sheet metal. After the hot water washes the metal feed stock, it proceeds back to the washer tank where oil is removed through filtration and centrifugation prior to reuse. The metal feed stock then proceeds through another set of air knives to prevent contamination of wash fluid and rinse fluid, where it then enters the rinse station. The rinse station is comprised of cartridges comprising two rolls stacked on top of each other made of either chrome or fibrous material. The cartridges also contain spray headers that rinse above and below the washed metal feed stock with hot water drawn from the rinse tank which is approximately 99.9% free of oil. After the rinse, the rinse water is returned to the rinse tank where the remaining oil is removed through filtration and centrifugation. The rinsed metal feed stock proceeds through another set of air knives designed to remove the standing rinse water for recycling and proceeds to a heated blow dry that removes the moisture on the metal feed stock. The liquid runoff and mist created from the air knives is contained through the integral “O” Mist Containment/Removal System that prevents steam and liquid from escaping the system and cycles it to a mist collection unit that allows the steam to be deposited outside the confines of the building and returns the liquid water to the tanks for reuse. 
         [0013]    Each cartridge uses individual drive motors driving one or both of the rolls used in the wash and rinse units. The use of individualized motors reduces noise, facilitates easier maintenance and allows repairs of the individual rolls to occur as necessary. The cartridge system allows for introduction of more cartridges to a system if needed. Each cartridge controls the pressure between the two rolls using pneumatic power or machine screw jacks and can adjust at pre-determined pressures to vary between the thicknesses of metal feed stock running through the washing process. 
         [0014]    Both the wash and rinse water tanks contain multiple levels of filtration to ensure clean water. Complete in both water tanks are oil separator, high speed centrifuge, screen filters, rare earth magnets, bacterial filtration, carbon monitoring equipment, particle filtration and heating system. The wash tank replenishes water lost to evaporation through a pump system that draws water from the rinse tank. The rinse tank is re-supplied with reverse osmosis treated water. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0015]      FIG. 1  shows the top-down view over the entire multi-stage flat sheet metal wash system with the service platform removed. 
           [0016]      FIG. 2  shows the wash and rinse system with the motors and pipes removed. 
           [0017]      FIG. 3  shows the wash and rinse system with air knives with the frame removed to reveal the inner profile. 
           [0018]      FIG. 4  shows the heated blow dry system. 
           [0019]      FIG. 5  shows the front profile of the wash/rinse system. 
           [0020]      FIG. 6  shows the top of the washer tank. 
           [0021]      FIG. 7  shows a rear view of the washer tank. 
           [0022]      FIG. 8  shows a top side view of the washer tank with the overhead panels removed. 
           [0023]      FIG. 9  shows a top view of the rinse tank. 
           [0024]      FIG. 10  shows a rear view of the rinse tank. 
           [0025]      FIG. 11  shows a top side view of the rinse tank with the overhead panels removed. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0026]      FIG. 1  shows the aerial, top-down view of the entire multi-stage processed flat sheet metal wash system. In the lower left-hand corner is the entrance  1  for the metal feed stock where it flows into the first air knife  2 , wash coil stage  3 , middle air knife  4 , rinse coil stage  5 , end air knife  6 , and finally exits  8  after proceeding through a heated blow dry  7 . The service platform  10  is located behind the entire wash/rinse stage and spans from the entrance to the metal feed stock  1  all the way to the mist collector  11  located beyond the opposite end of the wash/rinse stage. Coil wash/rinse stage begins with an air knife system with air knife located on the top of the metal feed stock. From the air knife, the metal feed stock proceeds to the right in the washer stage that consists of eight rollers (shown on  FIG. 2 ). From the washer stage, the metal feed stock proceeds through an air knife system comprising an air knife located on the top and bottom of the metal feed stock. The metal feed stock further proceeds to the right where it enters a rinse stage comprising four rollers (shown on  FIG. 2 ). From there the metal feed stock proceeds through another air knife, comprising air knives on the top and bottom of the metal feed stock, where it finally proceeds through a heated blow-off  7  that blows heated air diagonally across the metal feed stock. The heated blow off  7  is supplied by the heated blow off stage  19  located directly behind the heated blow off  7 . The metal feed stock then exits the system  8  and can be inspected and recoiled for storage or shipping (not shown). The wash/rinse stage is supported by a metal frame  130  (shown on  FIG. 4 ) to allow for piping to be connected from underneath the unit. 
         [0027]    Coatings typically include oil or some other corrosion preventative and other debris that can accumulate on processed metal stock. The oil is then extricated from water through high speed centrifuges and recycled, leaving the water approximately 99.0% oil-contamination free. For steel it is often desirable to remove all of the contaminants and leave a small amount of oil to prevent flash rusting, in the case of a metal feed stock that rusts, and allow for storage. 
         [0028]    Adjacent to the wash/rinse stage is a service platform  10  with stairwell entrance  12 . The metal support platform provides access for operators to the different components of the entire system. The air knifes  2 ,  4 ,  6  are supplied with high speed ambient air from the air blower  9  located under the service platform  10  in line with the middle air knife  4 . The space underneath the service platform  10  allows multiple metal pipes to travel from the wash/rinse stage to various components of the system. 
         [0029]    Wash discharge pipe  13  leads from underneath the wash unit  2  perpendicular to the flow of metal feed stock, underneath the service platform  10 , and connects to the washer filtration unit  15  via the juncture  14  located on the upper corner along the long face of the wash filtration unit  15 , proximal to the air blower  9 . Rinse discharge pipe  16  leads from underneath the rinse unit  5 , proceeds underneath the service platform  10 , parallel to the wash discharge pipe  13  before angling 45 degrees away from the wash discharge pipe  13  and connecting to the rinse filtration unit  18  via juncture  17  located on the upper corner along the long face of the rinse filtration unit  18 . Mist collection pipes (shown on  FIG. 5 ) emerge from the top of the wash unit  3  and rinse unit  5  and combine into main mist collection pipe  20  which travels along the base of the wash/rinse stage, under the service platform  10  to the mist collector  11 . From the mist collector  11  released mist exits through the exit pipe  21  mounted on mist collector  11 . 
         [0030]    Located behind the wash stage  3  and the wash manifold  149  is the hydro-carbon testing unit  191 . It is mounted to the handrail  190  that surrounds the service platform  10 . The hydro-carbon testing unit  192  serves the rinse tank and is located on the handrail  190  located adjacent to the mist collector  11 . The hydro-carbon testing unit  191 ,  192  measures the quantity of the oil and the quality of the water within the tanks. Additionally it can track the oil quantity over a period of time to facilitate maintenance. 
         [0031]    Referring to  FIG. 2 , uncoiled metal feed stock enters the unit at the entry point  1 , through the splash guard and enters the first air knife  2 . The high speed ambient air is utilized to maintain pressure keeping water from exiting the system and to remove any debris. The uncoiled metal feed stock then enters the first wash cartridge  31  where it is met by an upper  35  and lower hard chrome roll  36 . The upper roll  35  is supported on each end by a bearing housing with spherical roller bearings  39 . A pneumatic cylinder  41  is mounted on top of the wash cartridge top frame portion  31   b  and connects to the bearing housing with spherical roller bearings  39  via attachment plate  40 . When the pneumatic cylinder actuates, the attachment plate  40 , bearing assembly  39 , and subsequently the upper roll  35  slide vertically to meet the lower chrome roll  36  and provide a specified pressure. The lower chrome roll  36 , mounted directly underneath the upper chrome roll  35 , is supported on each side by a bearing housing with spherical roller bearings  43   a  which is connected to an attachment plate with manual adjusting screws with attachment plate  38  that allow the lower roll  36  to slide vertically to match the roll to pass-line height. The attachment plate with manual adjusting screws  38  is attached to the wash cartridge  31  at bottom frame portion  31   a.  The lower chrome roll  36  is driven by a motor and speed reducer  43  (shown on  FIG. 5 ) through the drive shaft  42 . Each cartridge will use individual drive motors driving one or both of the rolls used in the wash and rinse units. A purpose of the individualized motors is to reduce noise, facilitate easier maintenance and allow repairs of the individual rolls to occur as necessary. The cartridge system also allows for introduction of additional cartridges to a system when needed. Each cartridge allows controlling the pressure between the two rolls using pneumatic power or machine screw jacks and can adjust at pre-determined pressures to vary between the thicknesses of metal feed stock running through the washing process. 
         [0032]    The upper chrome roll  35  is not motor driven but moves along with the uncoiled metal feed stock by friction. Located behind the upper and lower chrome rolls are spray headers  37  (shown on  FIG. 3 ) that dispense hot wash water onto the metal feed stock to assist in removal of the oil. The water is approximately 200° F. The entire first wash cartridge  31  is singularly contained and bolted all four corners to the washer frame (not shown). Once the bolts are removed the lift rings  34  located at each corner can be used to lift the cartridge from the washer frame. This allows the entire cartridge to be removed, complete with both rolls, pneumatic cylinder slides and spray headers for repair or scheduled maintenance. The metal top  46  extends across the entire wash cartridge  31  and prevents mist and liquid from escaping the wash cartridge. Opening  47  located in the middle of the metal top  46  is where the front mist collection pipe  22  connects. Mist generated in the first and second wash cartridges is taken through the front mist collection pipe  22  and connects with main mist collection pipe  20  that leads to the mist collector  11  (shown on  FIG. 1 ,  5 ). 
         [0033]    The metal feed stock is then fed into the second cartridge  48  where the upper roll  49  is an abrasive embedded non-woven roll and is supported on each end by a bearing housing with spherical roller bearings  50  with an attachment plate  51  that allows the upper roll  49  to slide vertically to meet the lower chrome roll  52  and provide a specified pressure. The abrasive or scouring roll may be a non-woven material that acts as an abrasive or scouring material. The roll should be a tough, highly conformable, sharp-cutting, non-woven abrasive for cleaning and finishing surfaces. The attachment plate  51 , controlling the upper roll  49 , is connected to a jack assembly  56  as a part of the automatic pass line adjustment mounted on top of the second wash cartridge frame  48   b  on both ends. The shaft  57  connects both the jackscrew assemblies  56  as well as the encoder arrangement (not shown) gear motor (not shown). If adjustment is needed, the automatic pressure adjustment initiates the gear motor that turns the jackscrew assembly allowing the attachment plate  51  to move vertically to adjust the pressure of the roll. The lower chrome roll  52 , mounted directly underneath the upper abrasive embedded non-woven roll  49 , is supported on each side by a bearing housing with spherical roller bearings  53  which is connected to an attachment plate with manual adjusting screws  54  that allow the lower roll  52  to slide vertically to match the roll to pass-line height. The attachment plate with manual adjusting screws  54  is attached to the wash cartridge  48  at bottom frame portion  48   a.  The lower roll is a hard chrome roll identical to those used in the first cartridge zone  31  and is driven by a motor and speed reducer  58  through shaft  55 . The upper roll  49  is driven by a motor and speed reducer  59  through shaft  60  that is located on the opposite side as the motor and speed reducer that drives the lower roll. When the uncoiled metal feed stock is being fed into the second wash cartridge  48 , the upper roll  49  rotates with the metal feed stock helping it thread between the rolls. Once the uncoiled metal feed stock is threaded properly, the upper roll rotates against the direction of the metal feed stock to further facilitate the cleaning process and removal of the deposited oil. The second wash cartridge facilitates the cleaning of the top of the coiled metal feed stock. Spray headers  61  located on either side of the upper and lower rolls spray water that is at 200° F. to help wash off the oil (shown on  FIG. 3 ). The second wash cartridge  48  is singularly contained and bolted on all four corners to the washer frame (not shown) to allow for easy removal. Once the bolts are removed the lift rings  62  located at each corner can be used to lift the cartridge from the washer frame. This allows the entire cartridge to be removed, complete with both rolls, machine screw jacks and spray headers for repair or scheduled maintenance. Metal top  63  encloses the second wash cartridge  48  to prevent mist and liquid from escaping. 
         [0034]    The metal feed stock is then fed into the third cartridge  64  which is the same construction as the second wash cartridge  48  but reversed with the chrome roll on the top and the abrasive embedded non-woven roll on bottom. The lower roll  65  is an abrasive embedded non-woven roll and is supported on each end by a bearing housing with spherical roller bearings  71  with an attachment plate  72  that allows the lower roll  65  to slide vertically to meet the upper chrome roll  66  and provide a specified pressure. The lower roll  65  is driven by motor and speed reducer  67   a  and the upper roll  66  is driven by motor  67   a  (shown on  FIG. 1 ) through drive shaft  68 . The attachment plate  72 , controlling the lower roll  65 , is connected to a jack assembly as a part of the automatic pass line adjustment mounted on the bottom of the third wash cartridge frame  64   a  on both ends (not shown). The shaft connects both the jackscrew assemblies as well as the encoder arrangement gear motor (not shown). If adjustment is needed, the automatic pass line adjustment initiates the gear motor that turns the jackscrew assembly allowing the attachment plate  72  to move vertically to adjust the pressure of the roll. The upper chrome roll  66 , mounted directly above the lower abrasive embedded non-woven roll  65 , is supported on each side by a bearing housing with spherical roller bearings  69  which is connected to an attachment plate with manual adjusting screws with attachment plate  70  that allow the upper roll  66  to slide vertically to match the roll to pass-line height. The attachment plate with manual adjusting screws  70  is attached to the wash cartridge  64  at top frame portion  64   b.  Spray headers  73  are located on either side of the rolls and dispense hot water onto the metal feed stock (shown on  FIG. 3 ). The lower roll rotates against the direction of the metal feed stock facilitating removal of deposited oil on the underneath of the uncoiled metal feed stock. The third wash cartridge  64  is singularly contained and bolted on all four corners to the washer frame (not shown) to allow for easy removal. Once the bolts are removed the lift rings  74  located at each corner can be used to lift the cartridge from the washer frame. This allows the entire cartridge to be removed, complete with both rolls, machine screw jacks and spray headers for repair or scheduled maintenance. Metal lid  75  encloses the third wash cartridge  64  to prevent liquid and mist from spilling or escaping into the air. Middle mist collection pipe  23  connects to the middle of metal lid  75  at opening  76  and exhausts mist collected in the wash stage and pipes it to main mist collection pipe  20  that then leads to mist collector  11  (shown in  FIG. 5 ). Similar to the second wash cartridge  48 , the third wash cartridge contains a an automatic upward pressure adjustment  77  (shown on  FIG. 3 ), located underneath the lower roll  65 , complete with a gear motor, jackscrew and encoder arrangement to adjust the down pressure of the roll to ensure proper cleaning of the uncoiled metal feed stock as it is washed. 
         [0035]    The metal feed stock then proceeds into the fourth and final washer cartridge  78  comprised of two identical fibrous rolls that work to remove excess liquid from both sides of the metal feed stock. The upper roll  79  is supported on each end by a bearing housing with spherical roller bearings  80 . A pneumatic cylinder  82  is mounted on the top frame portion  78   b  and connects to the bearing housing with spherical roller bearings  80  via attachment plate  81 . When the pneumatic cylinder actuates, the attachment plate  81 , bearing assembly  80 , and subsequently the upper roll  79  slide vertically to meet the lower fibrous roll  83  and provide a specified pressure. The lower fibrous roll  83 , mounted directly underneath the upper fibrous roll  79 , is supported on each side by a bearing housing with spherical roller bearings  84  which is connected to an attachment plate with manual adjusting screws with attachment plate  85  that allow the lower roll  83  to slide vertically to match the roll to pass-line height. The attachment plate with manual adjusting screws  85  is attached to the wash cartridge  78  at bottom frame portion  68   a.  The lower fibrous roll  83  is driven by motor  86  through drive shaft  87  (shown in  FIG. 1 ). Spray headers  88  are located preceding the fibrous rolls (shown on  FIG. 3 ). The fourth wash cartridge  78  is singularly contained and bolted on all four corners to the washer frame (not shown) to allow for easy removal. Once the bolts are removed the lift rings  89  located at each corner can be used to lift the cartridge from the washer frame. This allows the entire cartridge to be removed, complete with both rolls, pneumatic cylinder slides and spray headers for repair or scheduled maintenance. The metal lid  90  spans across the cartridge and encloses it keeping the liquid and mist from escaping. 
         [0036]    The uncoiled metal feed stock then exits the fourth wash cartridge  78  and enters the second air knife  4  that contains jets of air on both the top and bottom of the metal feed stock (shown in  FIG. 3 ). The purpose of this air knife is to prevent cross contamination between the wash fluid and the rinse fluid. 
         [0037]    The uncoiled metal feed stock then enters the entry rinse cartridge  90  where it is met by an upper  91  and lower hard chrome roll  95 . The upper roll  91  is supported on each end by a bearing housing with spherical roller bearings  92 . A pneumatic cylinder  94  is mounted on top frame portion  90   b  and connects to the bearing housing with spherical roller bearings  92  via attachment plate  93 . When the pneumatic cylinder actuates, the attachment plate  93 , bearing assembly  92 , and subsequently the upper roll  90  slide vertically to meet the lower chrome roll  95  and provide a specified pressure. The lower chrome roll  95 , mounted directly underneath the upper chrome roll  91 , is supported on each side by a bearing housing with spherical roller bearings  96  which is connected to an attachment plate with manual adjusting screws with attachment plate  97  that allow the lower roll  95  to slide vertically to match the roll to pass-line height. The attachment plate with manual adjusting screws  97  is attached to the rinse cartridge  90  at bottom frame portion  90   a.  The lower chrome roll  95  in the entry rinse cartridge  90  is driven by a motor and speed reducer  98  through the drive shaft  99  (shown in  FIG. 5 ). The upper chrome roll  91  is not motor driven by moves along with the uncoiled metal feed stock. Located behind the upper and lower chrome rolls are spray headers  100  that dispense hot rinse water onto the metal feed stock to assist removal of oil (shown on  FIG. 3 ). The water is approximately 160° F. The entire entry rinse cartridge  90  is singularly contained and bolted all four corners to the rinse frame (not shown). Once the bolts are removed the lift rings  101  located at each corner can be used to lift the cartridge off the rinse frame. This allows the entire cartridge to be removed, complete with both rolls, pneumatic cylinder slides and spray headers for repair or scheduled maintenance. Metal lid  102  encloses entry rinse cartridge  90  and prevents mist and liquid from escaping. 
         [0038]    The metal feed stock then proceeds into exit rinse cartridge  103  comprised of two identical fibrous rolls that work to remove excess liquid from both sides of the metal feed stock. The upper roll  104  is supported on each end by a bearing housing with spherical roller bearings  105 . A pneumatic cylinder  107  is mounted on the top frame portion  103   b  and connects to the bearing housing with spherical roller bearings  105  via attachment plate  106 . When the pneumatic cylinder actuates, the attachment plate  106 , bearing assembly  105 , and subsequently the upper roll  104  slide vertically to meet the lower fibrous roll  108  and provide a specified pressure. The lower fibrous roll  108 , mounted directly underneath the upper fibrous roll  104 , is supported on each side by a bearing housing with spherical roller bearings  109  which is connected to an attachment plate with manual adjusting screws with attachment plate  110  that allow the lower roll  108  to slide vertically to match the roll to pass-line height. The attachment plate with manual adjusting screws  110  is attached to the rinse cartridge  103  at bottom frame portion  103   a.  The lower fibrous roll  108  is driven by motor  111  through drive shaft  112  (shown on  FIG. 5 ). A spray header  113  is located preceding the fibrous rolls (shown on  FIG. 3 ). The exit rinse  103  is singularly contained and bolted on all four corners to the rinse frame (not shown) to allow for easy removal. Once the bolts are removed the lift rings  114  located at each corner can be used to lift the cartridge off the rinse frame. This allows the entire cartridge to be removed, complete with both rolls, pneumatic cylinder slides and spray headers for repair or scheduled maintenance. Metal lid  128  encloses the exit rinse cartridge  103  and prevents mist and liquid from escaping the unit. Connection  116  located in the middle of metal lid  128  is where end mist collection pipe  24  connects to the exit rinse cartridge  103  and collects the mist generated by the rinse stage (shown on  FIG. 5 ). The end collection mist pipe  24  leads to the end air knife  6  before connecting with main mist collection pipe  20  (shown on  FIG. 5 ). 
         [0039]    Referring to  FIG. 3 , the interior of the wash, rinse and air knife system is exposed. The uncoiled metal feed stock enters into front air knife  2  that consists of one air knife that extends the width of the metal feed stock and blows high speed ambient temperature onto the top of the metal feed stock through air knife  115 . The middle air knife  4 , located between the wash stage  2  and rinse stage  4 , utilizes a pair of air knives  116  that extend the width of the metal feed stock and face towards the fourth wash cartridge  78 . The pair consists of an air knife that faces the top of the metal feed stock and an air knife that faces the bottom of the metal feed stock but angled towards the fourth wash cartridge  78  to blow any wash liquid back within the wash housing and to prevent liquid from the wash stage contaminating the rinse stage. The middle air knife  4  also contains an air knife  117  that is located on top of the metal feed stock and blows towards the entry rinse cartridge  90  to maintain pressure and prevent rinse liquid from escaping the rinse stage. The end air knife  6 , located after the rinse stage, contains a pair of air knives  118  facing the exit rinse cartridge with an air knife mounted for the top of the metal feed stock and an air knife mounted for the bottom of the metal feed stock. These air knives  118  prevent rinse liquid from escaping the rinse stage and removes standing water on the metal feed stock before it enters the heated blow dry  7 . 
         [0040]    The spray headers  37 ,  61 ,  73 ,  88 ,  100 ,  113  are all designed the same with nozzles equally dispersed along the header. The header extends the width of the metal feed stock and allows for even distribution of spray water along the metal feed stock. Each cartridge contains an upper and lower header to spray the upper and lower sides of the uncoiled metal feed stock respectively. The first wash cartridge  31  has one pair of spray headers  37  which are located directly behind the upper and lower rolls. The second wash cartridge  48  contains two pairs of spray headers  61  with the first set located preceding the rolls and the second set located after the rolls. The third wash cartridge  64  has two pairs of spray headers  73  arranged in the same manner as the second wash cartridge  48 . The fourth wash cartridge  78  contains only one pair of spray headers  88  located directly preceding the fibrous rolls. The entry rinse cartridge  90  utilizes one pair of spray headers  100  located after the chrome rolls and the exit rinse cartridge utilizes one pair of spray headers  113  located preceding the fibrous rolls. 
         [0041]    The wash spray headers  37 ,  61 ,  73 ,  88  utilize wash water from the wash filtration unit  15  via the wash fluid manifold  149  that is heated to approximately 200° F. and contains approximately 1 percent of oil contamination (shown on  FIG. 1 ). Typically the spray headers dispense approximately 250 gallons per minute onto the metal feed stock. The rinse spray headers  100 ,  113  utilize rinse water from the rinse filtration unit  18  via the rinse fluid manifold  179  that is heated to approximately 160° F. and contains approximately 1/10th percent of oil contamination (shown on  FIG. 1 ). Typically the rinse spray headers dispense rinse fluid at a rate of 150 gallons per minute. 
         [0042]    Referring to  FIG. 4 , the frame  119  supports the heated blow dry stage  19  and air knives  7 . The uncoiled metal feed stock proceeds directly from the end air knife  6  (shown on  FIG. 1 ) into the recirculation duct  120  and into the heated blow dry air knife plenum  7 . When the system is operating the blower fan  121  forces air into the air knife plenum  7  where it is then re-circulated through duct  120  into the mixing box  123 . Mixing box  123  has a filtered fresh air inlet and mixes the fresh air with the re-circulated air. Located underneath the blower fan  121  is the natural gas burner unit  122  that heats the air in the mixing box  123 . The blower fan  121  uses the heated air from mixing box  123  and forces it into the air knife plenum  7  where the heated air is blown on both sides of the metal feed stock to remove moisture. 
         [0043]    Referring now to  FIG. 5 , the washer frame  124  and rinse frame  126  are constructed of metal feed stock plate, structural stainless metal feed stock tubing, insulation and metallic sheet metal. All mounting surfaces are machined to insure proper fit and alignment. The head-section is enclosed in aluminum, with covers on top and sides of the unit. Splash guards are positioned at the material entry and exit points. All machined surfaces are nickel-plated. The housing utilizes multiple mating members&#39; guides and supports several interchangeable cartridges. The wash and rinse frames are supported by a metal frame  130 . The wash frame  124  is located underneath the four wash cartridges and contains a drain  125  located in the middle of it. The design of the wash frame  124  allows all wash fluid delivered via the spray headers to flow into the drain  125  and into the wash drain pipe  13 . The wash drain pipe  13  flows directly down before curving 90° perpendicular to the wash stage. The wash drain pipe then proceeds along before making another 90° curve parallel to the wash stage in the direction of the flow of metal feed stock and connects to the wash filtration  15  (shown on  FIG. 1 ). The rinse frame  126  is located underneath the two rinse cartridges and contains a drain  127  located in the middle of it. The design of the rinse frame  126  allows all rinse fluid delivered via the spray headers to flow into the drain  127  and into the rinse drain pipe  16 . The rinse drain pipe  16  extends straight down out of the rinse frame  126  before curving 90° perpendicular to the rinse stage. The rinse drain pipe  16  then proceeds along before making another 90° curve parallel to the rinse stage in the direction of the flow of metal feed stock and connects to the rinse filtration  18  (shown on  FIG. 1 ). 
         [0044]    The “O” Mist Containment/Removal System includes the ambient high-speed blow off air knives  2 ,  4 ,  6  as well as the pipe system that contains the mist and routes the liquid to the mist collector  1 . The ambient high-speed blow-off air knives are supplied by air through the high speed air blower  9  located underneath the service platform  10  and behind the wash/rinse stage. From the high speed air blower, a pipe  29  extends underneath the middle air knife  4  before making a 90° curve to enter the middle air knife  4  from its front underside. Air travels from this pipe  29  and into the blower  115  (shown in  FIG. 3 ). Before the main handler pipe  29  makes the 90° curve into the middle air knife  4 , a smaller pipe  28  connects with it and curves 45° towards the side of wash stage and then connects with the front underside of the front air knife  2 . Air from this pipe  28  supplies the blowers  116 ,  117  located in the front air knife  2  (shown on  FIG. 3 ). A second pipe  30  emerges from the main air handler pipe  29  prior to the front air handler pipe  28 . This pipe is larger than the front air pipe  28  but smaller than the main air pipe  29  and angles 45° towards the side of the rinse stage before curving 90° and joining the end air knife  6  at its front underside. The end air pipe  30  supplies the air to the blowers  118  in the end air knife  6  (shown in  FIG. 3 ). 
         [0045]    The front mist collector pipe  22  extends from the middle of metal lid  46  at opening  47  (shown on  FIG. 2 ) proceeds to connect with the front air knife  2  on top rear side. The mist is collected through negative pressure and flows into the main mist collection pipe  20  that emerges on the underside of air knife  2  on the same side as the front mist collector pipe  22  enters. The main mist collector pipe  20  runs parallel to the wash/rinse stage and ends at the mist collector  11 . The middle mist collector pipe  23  extends from the metal lid  75  at opening  76  and connects to the top of middle air knife  4  on the same side as the front mist collector pipe  22 . Through negative pressure the mist from the washer unit is drawn into the middle mist collector pipe  23  and runs through the middle air knife  4  and empties into the main mist collector pipe  20 . The end mist collector pipe  24  extends from the metal lid  128  through opening  129  and connects to the top of end air knife  6  on the same side as the front mist collector pipe  22 . Through negative pressure the mist from the rinse unit is drawn into the end mist collector pipe  24  and runs through the end air knife  6  and empties into the main mist collector pipe  20  that deposits into the mist collector  11 . 
         [0046]    The mist collector  11 , located adjacent to the rinse tank  161  extends perpendicularly and contains an exhaust pipe  21  to vent mist into the atmosphere. The mist collector  11  also has a tank that collects the remaining water/oil mixture and pumps back to the wash tank via pipe (not shown). The unit is utilized to prevent moisture from escaping into the wash area and to provide a recycling apparatus capable of returning liquid back into the system. 
         [0047]    Referring now to  FIG. 6 , the washer drain pipe  13  connects to the washer drain pan  125  underneath the middle wash cartridges traveling underneath the service platform  10  (shown on  FIG. 1 ) before connecting  14  to the washer tank  131  at the upper corner of the long face of the tank. The metallic washer tank  131  is rectangular in shape with the shorter side of it facing the wash cartridge assemblies. Once inside the wash tank  131 , the water from the washer drain pipe  13  flows in a counter clockwise rotation, mixing with tank fluid and passing over the serpentine heating tube  156  (shown on  FIG. 8 ). The end barrel mount water pump  132 , mounted on top of the tank, is located on the same side as the washer drain pipe entrance  14  but on the opposite end. 
         [0048]    The washer tank  131  contains several exterior features such as two cleanout doors, two top tank access doors and a railing encompassing half of the washer tank excluding the oil separator. The first cleanout door  133  is located on the long face of the washer tank  131  proximal to the water entrance  14 . A second cleanout door  134  (shown on  FIG. 7 ) is located at the rear of the wash tank on the short face, adjacent to the tube heating system  135 . The two top tank access doors are located in the rear of the washer tank and are positioned next to each other on top of the washer tank  131 . The top tank access door  136  at the edge of the washer tank  131  contains a hinged lid complete with frame  137 . Four rare Earth magnets  160  are attached to the top tank access door  136 . An operator opens the lid by using the manual gear box  153  located adjacent to the top tank access door  136  to open it for cleaning and monitoring of the magnets. When the lid is shut, the magnets are lowered within the wash tank and attract metallic materials. Operators can wipe the magnets down and provide a simple diagnostic test. The middle tank top access door  138  is located adjacent to the first top tank access door  136  and provides access to the oil sucker tube  139  (shown on  FIG. 8 ) that draws oil to the oil decanter  140 . The handrail  144  extends along the side of the washer tank on the opposite side of the oil decant separator  140  until approximately half way down the washer tank. From the half way point, the handrail  144  extends along the width of the washer tank before ending at the oil decant separator. The manual drain valve  155  is located at bottom rear of the washer tank on the short face and is used to drain the washer tank. The fluid sensors  154  extend perpendicularly from the tank and are located on the top of the washer tank between the water pump  132  and the exhaust pipe  157 . There are two fluid sensors for redundancy and are used to measure the level of fluid in the tank to ensure full capacity at all times. 
         [0049]    An oil decant separator unit  140 , with a high-temperature pneumatic pump system  141 , is mounted along the top of the washer tank  131 , situated on the long side just behind the connection  14  of the washer drain pipe  13 . The oil separator  140  uses a sucker tube  139  (shown on  FIG. 8 ) located at the top interior of the tank underneath the middle top tank access door  138 , to skim oil off the top of the water and remove it from the tank. The water flow in the tank is minimal at the location of the oil skimmer sucker tube  139  and as a result the oil coalesces at that location. The use of the oil separator eases the requirement of the centrifuges to filter out oil by eliminating standing oil in the washer tank. 
         [0050]    Mounted externally to the wash tank is an industrial large capacity high-speed centrifuge  145 . The centrifuge, utilizing an integral pump, takes water from the side of the wash tank (not shown) and separates the oil from the water. The oil is removed and deposited at a separate location for recycling and the cleaned water, containing approximately 1 percent oil contamination, is returned to the wash tank. Included is an automatic pre-filter package, cleaning pan and its own tank base (not shown). 
         [0051]    The barrel mount stainless metal feed stock wet end pump  132  is located at the rear of the wash tank on the same side as the oil separator  140 . The pump draws water in from an intake within the washer tank  131  and pumps it through a pipe  146  and into a set of externally mounted filters  147  located behind the wash tank  131 . A total of four filters take the piped in water and remove any particles over  40  micron in size. From filter unit  147 , the water travels through a pipe  148  that reenters the enclosed washer tank and runs underneath the long side of the wash tank underneath the oil separator before emerging on the opposite end of the wash tank. The pipe  148  emerges from the front of the wash tank  131  and proceeds to a manifold  149  that disperses the heated, cleaned, filtered water to the individual spray headers  37 ,  61 ,  73 ,  88 . Butterfly valves  150  are attached at the entrance of the micron filters  147  allowing the water to bypass one micron filter pair. When the micron filter valves are shut off for one pair, the water is piped to the other pair of micron filters. If the manual butterfly valves  150  are not shut off then the wash fluid enters both sets equally. A manual butterfly valve  151  is attached to the water pump allowing the system to be shut off as well as for throttling. A liquid filled pressure gauge is also attached to the water pump (not shown). 
         [0052]    Referring now to  FIG. 7 , two bacteria filters  142  are mounted externally on top of the washer tank  131 , approximately in the middle. Using a pneumatic pump  143  the wash liquid is drawn into the first canister that contains an oil absorbing material and then is piped into the second filter which contains a time release chlorine bag that kills any bacteria in the wash fluid. The treated wash water is then piped back into the tank. The removal and prevention of bacteria growth is necessary to prevent clogging of filters, pipes and centrifuges as well to prevent smell and other associated complications of bacteria growth. Emerging from the bottom of the bacteria filters  142  is a drain pipe  159  that extends along the top of the washer tank across its width. After reaching the edge of the washer tank, the drain pipe  159  drops immediately down to a drain along the side of the wash tank. The drain allows for the bacteria filters to be changed or undergo maintenance. 
         [0053]    Referring now to  FIG. 8 , featuring a top-down view of the interior of the wash tank  131 , a large serpentine heating tube  156  is contained within the wash tank. It begins in the rear of the wash tank where it is connected to a natural gas burner unit  135  which is mounted externally to the wash tank  131 , on the rear short side of the tank. The gas burner unit  135  supplies a heated gas flame through the serpentine heating tube  156  before ending at the exhaust pipe  157 . The loops span the width and length of the wash tank. The exhaust pipe  157  is located just behind the oil decant separator and extends perpendicularly out of the washer tank. Multiple support brackets  158  suspend the heating tube within the wash tank, keeping it approximately in the middle of the tank. The serpentine tube carries the flame and heats the water to a predetermined temperature such as 200° F. and maintains the temperature of the water throughout the tank. The heating system also contains a temperature modulator, thermostat control, and a low liquid level safety shut-off switch (not shown). 
         [0054]    Referring now to  FIG. 9 , the rinse drain pipe  16  connects to the rinse drain pan  127  underneath the two rinse cartridges traveling underneath the service platform  10  (shown on  FIG. 1 ) before connecting  17  to the rinse tank  161  at the upper corner of the long face of the tank. The metallic rinse tank  161  is rectangular in shape with the shorter side of it facing the rinse cartridge assemblies. Once inside the rinse tank  161 , the water from the rinse drain pipe  16  flows in a counter clockwise rotation, mixing with the tank fluid passing over the heated serpentine tube  186  (shown on  FIG. 11 ). The end barrel mount water pump  162 , mounted on top of the tank, is located on the same side as the rinse drain pipe entrance  17  but on the opposite end. 
         [0055]    The rinse tank  161  contains several exterior features such as two cleanout doors, two top tank access doors and a railing encompassing half of the washer tank excluding the oil separator. The first cleanout door  163  is located on the long face of the rinse tank  161  proximal to the water entrance  17 . A second cleanout door  164  is located at the rear of the rinse tank on the short face, adjacent to the tube heating system  165 . The two top tank access doors are located in the rear of the rinse tank and are positioned next to each other on top of the rinse tank  161 . The top tank access door  166  at the edge of the rinse tank  161  contains a hinged lid complete with frame  167 . Four rare Earth magnets  194  are attached to the top tank access door  166 . An operator opens the lid by using the manual gear box  183  located adjacent to the top tank access door  166  to open it for cleaning and monitoring of the magnets. When the lid is shut, the magnets are lowered within the wash tank and attract metallic materials. Operators can wipe the magnets down and provide a simple diagnostic test. The middle tank top access  168  door located in the middle provides access to the oil sucker tube  169  (shown on  FIG. 8 ) that draws oil to the oil decanter  170 . The handrail  174  extends along the side of the rinse tank on the opposite side of the oil decant separator  170  until approximately half way down the rinse tank. From the half way point, the handrail  144  extends along the width of the rinse tank before ending at the oil decant separator. The manual drain valve  185  is located at bottom rear of the rinse tank on the short face. The fluid sensors  184  extend perpendicularly from the rinse tank  161  and are located on the top of the rinse tank between the water pump  162  and the exhaust pipe  187 . There are two fluid sensors for redundancy and are used to measure the level of fluid in the tank to ensure full capacity at all times. 
         [0056]    An oil decant separator unit  170 , with a high-temperature pneumatic pump system  171 , is mounted along the top of the rinse tank  161 , situated on the long side just behind the connection of the rinse drain pipe  16 . The oil separator  170  uses a sucker tube  169  (shown on  FIG. 11 ) located at the top interior of the tank underneath the middle top tank access door  168 , to skim oil off the top of the water and remove it from the tank. The water flow in the tank is minimal at the location of the oil skimmer sucker tube  169  and as a result the oil coalesces at that location. The use of the oil separator eases the requirement of the centrifuges to filter out oil by eliminating standing oil in the rinse tank. 
         [0057]    Mounted externally to the rinse tank is an industrial large capacity high-speed centrifuge  175 . The centrifuge, utilizing an integral pump, takes water from the rinse tank and separates the oil from the water. The oil is removed and deposited at a separate location for recycling and the cleaned water, containing approximately 1/10th percent oil contamination, is returned to the rinse tank. Included is an automatic pre-filter package, cleaning pan and its own tank base (not shown). 
         [0058]    The barrel mount stainless metal feed stock wet end pump  162  is located at the rear of the rinse tank on the same side as the oil separator  170 . The pump draws water in from an intake within the rinse tank  161  and pumps it through a pipe  176  and into a set of externally mounted filters  177  located behind the rinse tank  161 . A total of four filters take the piped in water and remove any particles over 40 micron in size. From the filter unit  177 , the water travels through a pipe  178  that reenters the enclosed rinse tank and runs underneath the long side of the rinse tank underneath the oil separator before emerging on the opposite end of the rinse tank. The pipe  178  emerges from the front of the rinse tank  161  and proceeds to a manifold  179  that disperses the heated, cleaned, filtered water to the individual spray headers  100 ,  113 . Butterfly valves  180  are attached at the entrance of the micron filters  177  allowing the water to bypass one micron filter pair. When the micron filter valves are shut off for one pair, the water is piped to the other pair of micron filters. If the manual butterfly valves  180  are not shut off then the wash fluid enters both sets equally. A manual butterfly valve  181  is attached to the water pump allowing the system to be shut off as well as for throttling. A liquid filled pressure gauge is also attached to the water pump (not shown). 
         [0059]    Referring now to  FIG. 10 , two bacteria filters  172  are mounted externally on top of the rinse tank  161 , approximately in the middle. Using a pneumatic pump  173  the wash liquid is drawn into the first canister that contains an oil absorbing material and then is piped into the second filter which contains a time release chlorine bag that kills any bacteria in the rinse fluid. The treated rinse water is then piped back into the tank. The removal and prevention of bacteria growth is necessary to prevent clogging of filters, pipes and centrifuges as well to prevent smell and other associated complications of bacteria growth. Emerging from the bottom of the bacteria filters  172  is a drain pipe  193  that extends along the top of the rinse tank across its width. After reaching the edge of the washer tank, the drain pipe  193  drops immediately down to a drain along the side of the rinse tank. The drain allows for the bacteria filters to be changed or undergo maintenance. 
         [0060]    Referring now to  FIG. 11 , featuring a top-down view of the interior of the rinse tank  161 , a large serpentine heating tube  186  is contained within the rinse tank. It begins in the rear of the rinse tank where it is connected to a natural gas burner unit  165 . The natural gas burner unit  165  is mounted externally to the rinse tank  161 , on the rear short side of the tank. The gas burner unit  165  supplies a heated gas through the serpentine heating tube  186  before ending at the exhaust pipe  187 . The loops span the width and length of the rinse tank. The exhaust pipe  187  is located just behind the oil decant separator and extends perpendicularly out of the rinse tank. Multiple support brackets  188  suspend the heating tube within the rinse tank, keeping it approximately in the middle of the tank. The serpentine tube carries the heated gas and heats the water to a predetermined temperature such as 160° F. and maintains the temperature of the water throughout the tank. The heating system also contains a temperature modulator, thermostat control, and a low liquid level safety shut-off switch (not shown). 
         [0061]    The rinse tank contains a refill line  189  that draws in osmosis water to replace any liquid lost due to evaporation. The tank refill line  189  controls the osmosis fluid and automatically replaces lost water to the capacity of the rinse tank  161  of approximately 1500 gallons. The tank refill line  189  is located in between the oil decanter  170  and the exhaust pipe  187  and extends perpendicular from the rinse tank. A pneumatic pump pumps rinse water to the wash tank to refill it (not shown). The fluid sensors  184  on the rinse tank and the fluid sensors  154  on the wash tank determine the amount of water needed for each tank. The wash tank includes an osmosis system that draws water from the rinse tank into the wash tank to replenish water that has evaporated or been lost (not shown). The wash tank  131  capacity is approximately 2500 gallons. 
         [0062]    Before concluding, it is to be understood that the terminology employed in this application is for the purpose of describing particular embodiments. Unless the context clearly demonstrates otherwise, it is not intended to be limiting. In this specification and the appended claims, the singular forms “a,” “an” and “the” include plural references unless the context clearly dictates otherwise. Conversely, it is contemplated that the claims may be drafted to exclude any optional element or be further limited using exclusive terminology as “solely,” “only” and the like in connection with the recitation of claim elements or by use of a “negative” limitation. It is also contemplated that any optional feature of the inventive variations described herein may be set forth and claimed independently, or in combination with any one or more of the features described herein. 
         [0063]    Although the foregoing specific details describe various embodiments of the invention, persons reasonably skilled in the art will recognize that various changes may be made in the details of the apparatus of this invention without departing from the spirit and scope of the invention as defined in the appended claims. Therefore, it should be understood that, unless otherwise specified, this invention is not to be limited to the specific details shown and described herein.

Technology Classification (CPC): 1