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.