PHASE 1 RESEARCH PLAN -
Removal of Mercury from Contaminated Sites
Proposed by Edward Bogdan, Environmental Engineer
Document Property of:
American Computer Scientists Association Inc.
6 Commerce Drive, Suite 2000
Cranford, NJ 07016
Title of Project:
Mercury Mobil Reclamation Vehicle
Name and Title of Principal Investigator:
Edward Bogdan, Environmental Engineer / Research Scientist
Technical Abstract:
A process for reclaiming pure mercury amalgam from ground soils
contaminated with mercury by industrial processes. A mobile vehicle
which can be driven to contaminated field sites and which
can perform the mercury reclamation process.
Key Words:
Mercury, HGR2, Mobil, Environmental Cleanup, Recycling
Anticipated results/potential commercial applications.
Intended to be used to reclaim mercury at thousands of contamination
sites, and the reclaimed mercury amalgam is intended to be recyclable.
The mercury thus reclaimed can be used in nearly any industrial or
scientific process requiring pure mercury amalgam.
III. PROBLEM IDENTIFICATION & RESEARCH OPPORTUNITY
[Herein is proposed an in-situ treatment of Mercury-contaminated
soils using a field-use Mobile Processing Facility - the HG/MRV
(Mercury Mobile Reclamation Vehicle) which will use a proven
process for treating contaminated sites and reclaiming the
Mercury from them in an industrially pure amalgam which can be
re-used by industrial processes in today's safer and more
controlled manufacturing processes, where they are less
likely to re-contaminate the environment.]
There are many processes utilized for the manufacture of
caustic soda and chlorine. One such process, known as the
Diaphragm Cell Process, was used for half a century in the
United States.
The Diaphragm Cell process uses elemental mercury as a catalyst
in an electrolytic cell to convert sodium hypochlorite to chlorine.
A thin layer (less than one half inch thick) of mercury was placed
in each cell several months. The mercury was converted into a
mercury amalgam, eventually lost it's catalytic capabilities and
then discarded.
Millions of tons of chlorine was produced with Diaphragm Cells.
In turn, the process generated significant quantities of spent
mercury, which was discarded as a waste. The typical method of
disposal was burial in the facility grounds surrounding the
Diaphragm Cell operation.
Acres and acres of industrial property, predominantly in the
Gulf Coast and Pacific Coast regions of the country, are
contaminated with spent mercury amalgam. Often this "waste"
material is located no deeper than two feet from ground surface.
Mercury is an extremely toxic metal which can enter the human
body through the skin or through the respiratory system (vapors).
Storm water runoff can also transport soils contaminated with
mercury into adjoining watercourses. The hazards of water-borne
mercury and contamination of fish have been extensively researched
and published.
Little, if anything, has been done to promote removal of mercury
amalgam from these industrial soils. Unless those industrial
properties originally containing Diaphragm Cell, caustic
soda/chlorine facilities have recently undergone a change of
ownership or a plant closure, no regulatory program or economic
incentive has been put into place to promote such removal.
Over the past twenty five years, the Principal Investigator
has conducted, evaluated and refined an experimental physical/chemical
process for separation of mercury amalgam from soils. This process
has yielded mercury of an unquantified purity. For the purposes
of the Principal Investigator's study, this experimental process,
HgR3, will be used. If the purity can be shown to match the
purities needed for recycling into commercial applications, reuse
in other industrial processes, and/or reuse in industrial or
academic laboratories, then an economic incentive will exist.
The Association and Principal Investigator will retain exclusive
rights to the commercialized process.
The separation process will be designed for computer control and
for operation within a mobile facility, the HG/MRV. Computerization
will minimize staff requirements and mobility will promote
in-situ treatment. Both will enhance the economic incentive for
commercialization. The same processing system would most likely
be useful for remediation of other mercury contaminated sites.
IV. BACKGROUND, TECHNICAL APPROACH & POTENTIAL USES
A. BACKGROUND
The Diaphragm Cell Process for production of caustic soda and
chlorine is no longer utilized in this country. There were
over a dozen facilities with Diaphragm Cells in the United States
prior to conversion to more economic production methods. Site
conditions, production levels, quality control and proximity to
other chemical processes generating wastes discarded into the
same soils most likely vary significantly throughout the target
facilities.
Experimentation for separation of mercury amalgam from soils
was conducted at only on facility (which is now under new ownership).
Documentation does not exist. Scientifically valid experimentation,
testing all significant variables, is essential to determine
process capabilities, adaptability to computerization and economic
viability. It is noted that there may be many other industrial
waste sites equally applicable to this Research Program.
B. TECHNICAL APPROACH
Capabilities of the proposed separation process are to be examined
in a step wise approach. Permission will be obtained for access
to and removal of mercury contaminated soils from at least one
target facility. Permits will also be obtained for shipment of
these soils to the research facility. Bench sale experimentation
investigating all significant variables relating to the contaminated
soils from the first target facility, will be conducted while
obtaining similar permission from other target facilities.
Experimentation will then be conducted independently on soils
from each of the other target facilities. A comparative analysis
of results will be conducted to determine the following (not
necessarily all inclusive):
1. Variation in levels of purity (recovered mercury)
2. Variation in quantity of recovered mercury per known quantity
of soil
3. Effect of different target facility soil characteristics on
purities of recovered mercury
4. Presence/absence of other contaminants in the examines soils
and effect upon purity of recovered mercury.
Concurrently, the process variables will be examined to evaluate
applicability of available computer control technologies. The
potential for computerization will be approached in terms of
ease of operation, minimizing operating staff, optimizing spatial
requirements and assuring accuracy.
Economic viability will also be tested by comparing the projected
value (1996) of recovered mercury against recovery costs.
Numerous markets for resale of the recovered mercury may be
available, depending upon the purities obtained. Those markets,
purities required, quantities used and prices paid for "raw"
mercury will be examined as part of the economic analysis.
C. ANTICIPATED PHASE TWO RESULTS
The proposed research program will yield an automated process
for in-situ separation of mercury amalgam from previously
contaminated soils. At the completion of Phase 2, a prototype
of the automated mercury separation process will be available
for demonstration.
In addition to the completion of the prototype, the parameters
for commercialization will be completely defined. Markets for
the recovered mercury and specific users will be identified.
Corporate participation in the commercialized program will be
obtained from the predetermined target producers. This will
be accomplished by the development of an industry partnership
which will have an economic interest in the project.
Through operation of the partnership, the economies of mobilized,
in-situ soil remediation, mercury recovery and reuse will
become self evident due to the economic value of the
recovered mercury. Successful operation of mercury recovery
system (HgR) would promote expansion into mercury recovery from
other industries' waste sites.
The benefits to be derived from the development of this
cost-effective soil remediation, mercury recovery and
recycling (HgR3) program and it's successful commercialization
are significant and diverse. Among the most salient are:
1. Introduction of an economic incentive for target chlorine
producers to voluntarily remove and recover mercury from
on-site soils;
2. Recovery of a lethal toxin from soils and reduction
of associated human hazard potential;
3. Reduced potential for entry of mercury into the nation's
waterways and resultant contamination of fish and wildlife;
4. Reuse of a natural resource;
5. Reduced requirement for importation of mercury from
foreign suppliers;
6. In-situ treatment provides significant savings to affected
industries via reduction of soil transportation costs;
7. Savings in remediation costs (and perhaps, industry earnings
from project participation) frees up capital for research,
expansion, et al.;
D. SIGNIFICANCE OF PHASE 1 EFFORT
The process for physical separation of mercury amalgam
from soils which is the focus of this proposed research
program, invited evaluation of the potential commercial application.
Any such remediation, recovery and recycling program must be
the receptor of thorough and critical, technical, analytical,
economic and marketing analyses before being considered as a
viable candidate for commercial application.
Before embarking upon the full scale research program
(Phase 2), the pitfalls encountered during transition
from research to development, and from development to
commercialization must be completely understood. The Phase
1 Feasibility Study will provide Phase 2 project direction
by:
1. Identifying chlorine producers willing to participate
in the research program (and perhaps commercialization);
2. Developing a comprehensive picture of the regulatory,
technical, economic and market development hurdles which
must be overcome for successful commercialization;
3. Formulating cost-effective and human safety alternatives
based upon computer control; and
4. Defining the full extent of research variables which
must be examined during the laboratory analyses and bench
scale test runs.
V. PHASE 1 TECHNICAL OBJECTIVES
To determine project feasibility (Phase 1), a scientifically
accurate accounting of relevant variables affecting mercury
recovery and levels of purity must occur. That accounting
will include, but not necessarily be limited to evaluation
of the following:
1. Effects of different soils types and classifications
upon mercury recovery;
2. Effects of other soil contaminants upon mercury recovery;
3. Effect of laboratory equipment and processes utilized
upon ultimate purities obtained;
4. Relationship between purities obtained and the remediated
soils' classifications; and
5. Relationship between remediated soils' classifications
and resultant available disposal/reuse options.
The requested Phase 1 funds is required to develop and
execute a prototype research program capable of analyzing
these and other relevant project variables.
Success of the full scale program (Phase 2) is dependent
upon participation of target chlorine producers. Access to
their facilities and permission for removal and use of their
contaminated soils must be obtained. This would potentially
be accommodated by allowing the property owners a percentage
of the mineral rights in the resulting salvage. Receipt of
these approvals will be one of the primary Phase 1 objectives.
Future commercialization of the process will rely upon
market demand and market economics. The process must be able
to produce "recycled" mercury at purities and costs in synch
with that demanded by users. The process, it's economics and
production capabilities (purities) will be measured against
current and projected market demands. This assessment will
yield a scientifically based evaluation of true market potential.
The virtual nature of soil remediation, reclamation and
recycle calls for batch (discontinuous) operations. Another
objective of the Feasibility Study will be to determine
the potential for success and possible alternatives
available for adapting these batch processes to cost-effective,
automated, computer control.
VI. PHASE 1 WORK PLAN
A. Preparatory Research
While it is the applicant's intent to use the HgR3 process,
in preparation for the proposed operation, ACSA and the
Principal Investigator will be examining relevant studies
and parallel programs.
1. Currently & Past Heavy Metals Recovery Programs
The U.S. Environmental Protection Agency (USEPA), as well
as other federal and state agencies, have funded research
for innovative soil and ground water remediation technologies.
Many have involved heavy metals (such as mercury). Some of
the techniques investigated may have recovery options for
mercury or recovery options involving several heavy metals
including mercury.
ACSA will review USEPA documentation at their Edison,
New Jersey Library, industrial documentation available at
the Chemical Engineering Library in New York City, and
other relevant library sources to assess the following:
a. All relevant Heavy Metal recovery technologies
(including electro-kinetics) relevant to their capabilities
for mercury separation.
b. Synergistic and/or protagonistic effects of the presence
of more than one heavy metal upon soil separation.
c. Other processes utilized for heavy metal purification
subsequent to soil separation. Levels of purity obtained
by the different process.
d. Wastes and the resultant disposal problems generated
by the different technologies.
e. Comparative economics of soil separation and heavy
metal recovery.
The information obtained will be utilized to eliminate
redundant experimentation, provide focus upon the more
significant project variables and minimize laboratory
manpower and costs.
2. Determination of Governing Regulatory Constraints
ACSA will review all state and federal regulations (existing and
pending) relevant to the extraction, storage, treatment, shipment
and disposal of solid and hazardous wastes. This review will be
conducted to determine the following:
a. Classification of wastes/soils generated as byproducts of
separation and purification processes. Disposal/reuse options
permitted within the various classifications.
b. Potential handling and safety hazard problems generated by
the mercury separation activities (both experimental and
commercial)
c. Projection of costs generated by compliance requirements.
d. Quantification of benefits derived from in-situ treatment.
e. Legal and logistical issues requiring resolution prior to
commencement of laboratory experimentation and prior to
commercialization.
Such issues which may require resolution are:
- Transportation of hazardous waste to research facility
- Storage of contaminated soils during life of research program
- Storage, transportation and disposal of remediated soils
- Storage, transportation and reuse of recovered mercury
during life of research program.
Appropriate USEPA and other state/federal regulatory personnel
will be contacted to initiate resolution.
3. Identification of Caustic Soda/Chlorine Manufacturers
One pitfall I represented by the resistance of contaminated site
owners to be exposed to potential environmental liabilities. The
Principal Investigator will conduct research at the AIChE Chemical
Engineering Library to identify caustic soda/chlorine manufacturers
which, in the past have utilized electrolytic diaphragm cells in
the production of chlorine. The information sought will include,
at least, the following:
- Location of facility (s) and land survey maps;
- Operating volumes;
- Dates of operation with Diaphragm Cells;
- Original and current ownership;
- Corporate officers.
We will invite the corporate officers of the manufacturers whom
have contaminated sites to initiate discussions and conferences
regarding the intent of the Research Program. The goal of these
discussions will be to have at least one manufacturer enter into
an agreement providing Research Program participants with facility
access and the right to conduct on site experiments. We will also
attempt to interest at least one of these manufacturers in
participating in the Research Program (and perhaps, commercialization).
B. SOILS SAMPLING AND EXCAVATION
All soils have a layered appearance vertically. These layers,
or horizons vary in thickness. The uppermost horizon extends
from the surface to 3 to 12 inches deep, and is considered
the surface horizon. Most of the biological and weathering
activities within soils take place within the surface horizon.
Limited biological and weathering activity takes place in
the subsoil horizon(s). Most of the mineral material leached
from the surface horizon is deposited into the subsoil horizon(s).
Underlying the subsoil is the substratum. Little if any
weathering or biological activity takes place within this
horizon, although some percolation occurs, possibly carrying
contamination into the aquifer or groundwater system.
The different horizons and their soils content (sand, clay,
stone, minerals, moisture et al.) may have an effect upon
retention of mercury and the ultimate levels of purity
obtained, therefore, at least one mercury contaminated soil
sample will be excavated from each of the three soil
horizons within each soil classification selected for testing.
Various soils classifications (contaminated with mercury)
will be sampled to permit analytical determinations of the
effect (if any) of soils composition upon mercury retention,
mercury separation and purification. Proper testing will
identify the impact of different soils and the different
horizons within each of the soils upon the process's capabilities.
C. DEVELOPMENT/OPERATION OF PROTOTYPICAL PROCESS AND
LABORATORY FACILITIES
Successful commercialization of the proposed mercury
separation and purification process will depend upon a
comprehensive evaluation of, not only the process itself,
but also physical and chemical variables generated by market
demands, the composition of soils contaminated with mercury,
effects of other soil contaminants and other factors
that have yet to be determined. Therefore, an optimum
set of analytical tests will have to be devised to measure
the capabilities, adaptability, and feasibility of the
proposed process.
1. PROCESS SYSTEM DEVELOPMENT
A prototypical batch mercury separation and purification system
and analytical laboratory will be designed to include the following:
a. Soils handling system for process entry
b. Soils classification
c. Identification of soil borne contaminants
d. Soils storage according to classification and identified contaminants
e. At least four (4) treatment trains to minimize cross contamination.
These trains will include, but not be limited to:
- Mixers/agitators
- Solid/liquid chemical influents with
continuous weight/volume
- Measurements and recording devices
- Effluent product and byproduct discharge
and containment
- Mercury purification (i.e. distillation)
and storage
Additionally, procedures and tests will be developed for:
a. Determination of % purities obtained for mercury
b. Analysis and classification of by products/wastes
c. Clean out/decontamination
A comprehensive Health and Safety Plan will be prepared and
presented to all Program Participants prior to start up of these
facilities
2. PROCESS OPERATION (PHASE ONE)
For the purposes of testing this process operation, the ACSA HgR3
Lab will be augmented by the use of chemical laboratories and
test facilities at one of the local universities as part of a
$5,000 annual ACSA Grant Seeking Program.
At least twenty (20) distinct mercury separation and purification
test runs will be conducted in a scientifically controlled test
environment. The runs will be designed to provide an initial
evaluation of the individual effects of project variables upon
the process's capabilities to attain recyclable, commercial/research
grade mercury.
Test Run A - Effect of Soils Depth
One series of tests will be performed on mercury contaminated
soils excavated from the same area having just one soil
classification (i.e. Paxton well drained, moderately coarse
textured soils). A test run will be conducted on each of the
surface, subsoil and substratum horizons within that specific
soils classification.
Test Run B - Effect of Soils Classification
These test runs will be repeated for each additional soils
classification (contaminated with mercury) excavated from
participating chlorine producer sites.
Test Run C - Effects of Other Soil Contaminants
The presence of other contaminants along with mercury mat
alter the process's capabilities of mercury separation. There
may (or may not) be simple physical and/or chemical processes
available for removal of the other contaminants. Those soils
identified as having other contaminants will first be run
through the proposed process to determine synergistic/protagonistic
effects.
When mercury separation is impeded by the presence of other
contaminants, the potential for chemical and/or physical
solutions will be evaluated.
D. FEASIBILITY AND MARKET ANALYSIS (PHASE ONE)
The HgR study team will evaluate the products (different
purities of mercury) obtained against their potential for
commercialization. A cost estimate for recovering and
purifying mercury (on a per ounce basis) will be developed
utilizing the following assumptions:
- Separation/purification is conducted on-site. Cost estimates
for these processes will be based upon the costs incurred during
experimentation
- Target chlorine manufacturer has become a joint venture
partner. Access to and use of the target manufacturer's
facilities are gratis.
- 1996 manpower and equipment costs.
Potential industrial, commercial and research users for
the various grades of purified mercury will be identified.
Additional data relating to total U.S. mercury consumption,
user patterns, price variations during the past ten years,
volumes consumed by the different user categories, new
developing mercury markets, et al. will be analyzed.
The recycled mercury markets and their locations will
be evaluated as to their proximity to the target
chlorine manufacturers. Based upon this proximity, an
average transportation cost will be assigned to each
ounce of purified mercury made available for resale.
The HgR3 study team will then develop a preliminary
economic evaluation based upon estimated costs of
production. This evaluation will identify economic
opportunities and/or hurdles, requirements for cost
reduction, economic viability of computer control,
specific niches (some levels of purity may be too
expensive), and process refinements to be studied
during Phase 2.
E. COMPUTER CONTROL FEASIBILITY ANALYSIS
The HgR3 study team will attempt to design some of
the computer, automated control processes for the
mercury separation and purification identified
by the Principal Investigator. The relationships
between the individual processes (and sub-processes)
and the project variables effecting their performance
will be identified according to ease of automation,
i.e. control via predetermined and preset temperature,
pressure, volume, % humidity values.
The optimum forms of computer control for the
individual processes (soils handling, soils
classification, mercury separation, mercury
purification, discharge, handling, et al.) as
well as for the entire system, as a whole, will then
undergo a feasibility analysis. This analysis will
include consideration of the following: as well as for
the entire system, as a whole, will then undergo a
feasibility analysis. This analysis will include
consideration of the following:
- Ease of operation for the individual processes
- Ease of integration into one comprehensive
computer control system
- Spatial requirements
- Software, hardware and operational costs
- Manpower requirements
The advantages and disadvantages of computer control
will be evaluated in relation to the market analysis
performed in order to determine that an adequate
economic incentive exists for its utilization.
F. FINAL FEASIBILITY REPORT (PHASE ONE)
The HgR3 Study Team will prepare a Final Feasibility Report.
This report of findings will discuss the specific tasks
performed, observations made and significance of the
results obtained. Based upon these observations and
evaluations, ACSA will make recommendations for either
continuation of the Research Program or for its
termination. If continuation is recommended, ACSA will
identify the additional tasks required for
completion of Phase 2.
VII. PROJECT DESCRIPTION
A. PRIMARY PROJECT OBJECTIVES
The HgR3 Study Team will investigate the feasibility
of separating mercury amalgam from contaminated
soils, purifying the recovered mercury and establishing
viable markets for reuse/resale. The Phase 1 effort
will be directed towards the satisfaction of
four primary goals:
1. Obtain support from as least one chlorine
manufacturer
2. Develop and operate a prototypical mercury
separation and purification system
3. Develop a prototypical analytical laboratory
and analyze the effect of project variables upon
the system's performance
4. Determine economic viability and potential
for commercialization.
B. PROJECT DESCRIPTION (PHASE ONE)
The work to be performed consists of the following
six tasks:
Task #1. Preparatory research directed towards
the following:
a. Identification of caustic soda/chlorine
manufacturers in the United States who have
utilized electrolytic, diaphragm cells (which
used elemental mercury as a catalyst and discarded
spent mercury amalgam into adjoining soils.)
b. Identification of current and previous heavy
metal recovery programs. Determination of potential
application for soils which contain mercury amalgam
along with other heavy metals.
c. Identification and evaluation of solid waste and
hazardous waste regulations which may effect the
Research Program facility operations from project
inception through commercialization.
Task #2. Development and execution of a viable soil
sampling and excavation program which will permit
evaluation of a representative array of variables.
Task #3. Development and operation of prototypical
mercury separation/purification and analytical
laboratory facilities.
Task #4. Preliminary market analysis.
Task #5. Computer control feasibility analysis.
Task #6. Preparation of Final Report.
C. Performance Schedule (Phase One)
Task #1 to be completed within one (1) calendar
month after project initiation.
Task #2 to be completed within three (3) calendar
months after project initiation.
Task #3 to be completed within four (4) calendar
months after project initiation.
Task #4 to be completed within five (5) calendar
months after project initiation.
Task #5 to be completed within five (5) calendar
months after project initiation.
Task #6 to be completed within six (6) calendar
months after project initiation.
D. REPORTING REQUIREMENT
ACSA will prepare and submit a Final Report
documenting the standards utilized for process
operations and laboratory analyses. The Report
will provide comprehensive analyses of the following:
- Mercury separation process dynamics
- Mercury Purification process dynamics
- Market potential
- Potential commercialization pitfalls
- Economic viability, and
- Adaptability of process to automated computer control.
Recommendations for continuance or termination of
the Research Program will be based upon the contents
of these analyses.
VIII. RELATED RESEARCH
The Primary Investigator, Edward Bogdan, has conducted
many mercury amalgam separation experiments while under
the employ of one of this country's caustic
soda/chlorine manufacturers.
Spent mercury amalgam from one of the electrolytic
diaphragm cells was buried in the facility's adjoining
soils. Since the experimentation was aborted at this
stage, the level of success (% purity) was not determined
at the time.
IX. RESUME OF PRINCIPLE INVESTIGATOR / PERSONNEL
BACKGROUNDS.
The American Computer Scientists Association will
be providing several personnel of an administrative
nature to the effort, including legal services.
The following is the resume of PRINCIPLE INVESTIGATOR
Edward Bogdan.
EDWARD BOGDAN
ENVIRONMENTAL CONSULTANT
Edward Bogdan has provided environmental consulting
services, both as an independent consultant and
as president of his own firm for over twenty years.
His clients have included several of the Fortune Five
Hundred US corporations, architectural and engineering
firms, financial institutions, numerous municipalities
and the Government of Costa Rica.
Prior to forming his own environmental planning firm,
Mr. Bogdan worked as a staff chemical engineer at a
caustic soda/chlorine manufacturing facility in
Deer Park, Texas. At that facility he devised a pilot
plant operation for the removal of mercury from mercury
amalgam laden soil.
Mr. Bogdan, after receiving his MS in Sanitary/Environmental
Engineering from the University of California at Berkeley,
was a Sanitary Engineer with the US Environmental Protection
Agency (USEPA) in San Francisco, CA. He assisted in the
development of effluent guidelines and establishment of
compliance schedules for industrial pollutant dischargers.
Mr. Bogdan founded Quepco, Inc. in Pleasantville, NY in 1977.
This firm developed into one of the highly respected
environmental planning companies in the New York Metropolitan area.
Quepco, Inc. Specialized in the assessment of it's clients
regulatory problems, preparation of environmental documentation
and the processing of required permits.
More recently, Mr. Bogdan was Vice President of The Whitman
Companies, a New Jersey environmental Remediation firm. While
with this firm, he was responsible for the supervision of field
personnel and for the preparation of environmental documentation.
For the past several years Mr. Bogdan has been an independent
environmental consultant. He has prepared Phase I and
Phase II Environmental Audits and has provided clients
with other forms of environmental assistance upon request.
X. FACILITIES AND EQUIPMENT
To be allocated.
XI. CONSULTANTS AND CONTRACTORS
To be allocated.
XII. BUDGET
Contact the Association.
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