Process for removing mercury from brine sludges

Claim 2

A process for reducing the mercury content of mercury cathode brine electrolysis cell sludge containing minor concentrations of mercury by sequentially: (1) acidifying said sludge to a pH below 2.5, and (2) leaching said sludge with aqueous hypochlorite solvent of a pH above 5 until the mercury content is less than 0.75 part per million by weight based on the weight of sludge wet cake after leaching.

Claim 3

The process of claim 1 wherein the initial mercury content of the sludge wet cake is between 10 to 100 parts per million by weight based on the weight of sludge wet cake before acidifying.

Claim 4

The process of claim 1 wherein the sludge is acidified to a pH between zero and 2.2.

Claim 5

The process of claim 1 wherein the sludge is acidified with hydrochloric acid.

Claim 6

The process of claim 1 wherein the pH of the aqueous hypochlorite solvent is between 6 to 8.

Claim 7

The process of claim 1 wherein hypochlorous acid, sodium hypochlorite, calcium hypochlorite, or mixtures thereof constitute the major source of hypochlorite in the aqueous hypochlorite solvent.

Claim 8

The process of claim 1 wherein the sludge comprises saturator sludge or clarifier sludge.

Claim 9

The process of claim 1 wherein said cell sludge consists of saturator sludge.

Claim 10

A process for recovering and concentrating the mercury content of mercury cathode brine electrolysis cell sludge containing minor concentrations of mercury by sequentially: (1) acidifying said sludge to a pH below 2.5, (2) leaching said sludge with aqueous hypochlorite solvent at a pH above 5, (3) separating said solvent from the leached sludge, and (4) isolating the major part of the mercury content of said separated solvent.

Claim 11

A process for recovering and concentrating the mercury content of mercury cathode brine electrolysis cell sludge containing minor concentrations of mercury by sequentially: (1) acidifying said sludge to a pH below 2.5, (2) leaching said sludge with aqueous hypochlorite solvent at a pH above 5, (3) separating said solvent from the leached sludge, and (4) isolating the major part of the mercury content of said separated solvent.

Claim 12

The process of claim 9 wherein the initial mercury content of the sludge is between 10 to 100 parts per million by weight based on the weight of sludge wet cake before acidifying.

Claim 13

The process of claim 9 wherein the sludge is acidified to a pH between 1.0 and 2.2.

Claim 14

The process of claim 9 wherein the sludge is acidified with hydrochloric acid.

Claim 15

The process of claim 9 wherein the pH of the aqueous hypochlorite solvent is betweeen 6 to 8.

Claim 16

The process of claim 9 wherein hypochlorous acid, sodium hypochlorite, calcium hypochlorite, or mixtures thereof constitute the major source of hypochlorite in the aqueous hypochlorite solvent.

Claim 17

The process of claim 9 wherein the sludge comprises saturator sludge or clarifier sludge.

Claim 18

The process of claim 9 wherein the mercury content of the separated solvent is isolated by ion exchange, sorption, electrolytic deposition, metal replacement, amalgamation, oxidation, or sulfidation.

Claim 19

The process of claim 9 wherein the mercury content of the separated solvent is isolated by ion exchange, sorption, electrolytic deposition, metal replacement, amalgamation or oxidation.

Claim 20

In an improved process for making elemental chlorine and sodium-mercury amalgam by the electrolysis of brine in a mercury cathode electrolysis cell wherein depleted brine from said cell is treated with alkali-metal carbonate or alkali-metal hydroxide to precipitate impurities as clarifier sludge, said sludge containing minor concentrations of mercury, separating said sludge from said brine for disposal outside the cell, and adding to the electrolysis cell metallic mercury in amount at least equal to the mercury retained by said separated clarifier sludge; the improvement which comprises: recovering the mercury content of said sludge by sequentially: (1) acidifying said sludge with hydrochloric acid to a pH below 2.5, (2) leaching said sludge with aqueous hypochlorite solvent at a pH above 5, (3) separating said solvent from the leached sludge, (4) isolating the major part of the mercury content of said separated solvent, (5) converting the insolubilized mercury to metallic mercury or chloride of mercury, and (6) returning said metallic mercury to a cathode of a mercury cathode brine electrolysis cell.

Claim 21

In an improved process for making elemental chlorine and sodium-mercury amalgam by the electrolysis of brine in a mercury cathode electrolysis cell wherein depleted brine from said cell is treated with alkali-metal carbonate or alkali-metal hydroxide to precipitate impurities as clarifier sludge, said sludge containing minor concentrations of mercury, separating said sludge from said brine for disposal outside the cell, and adding to the electrolysis cell metallic mercury in amount at least equal to the mercury retained by said separated clarifier sludge; the improvement which comprises: recovering the mercury content of said sludge by sequentially: (1) acidifying said sludge with hydrochloric acid to a pH below 2.5, (2) leaching said sludge with aqueous hypochlorite solvent at a pH above 5, (3) separating said solvent from the leached sludge, (4) isolating the major part of the mercury content of said separated solvent, (5) converting the insolubilized mercury to metallic mercury or chloride of mercury, and (6) returning said metallic mercury to a cathode of a mercury cathode brine electrolysis cell.

Claim 22

In an improved process for making elemental chlorine and sodium-mercury amalgam by the electrolysis of brine in a mercury cathode electrolysis cell wherein depleted brine is reconcentrated by contact with solid sodium chloride and returned to said electrolysis cell, said contact with sodium chloride resulting in the accumulation of insoluble impurities as saturator sludge, said sludge containing minor concentrations of mercury, separating said sludge from said brine for disposal outside the cell, and adding to the electrolysis cell metallic mercury in amount at least equal to the mercury retained by said saturator sludge; the improvement which comprises: recovering the mercury content of said sludge by sequentially: (1) acidifying said sludge with hydrochloric acid to a pH below 2.5, (2) leaching said sludge with aqueous hypochlorite solvent at a pH above 5, (3) separating said solvent from the leached sludge, (4) isolating the major part of the mercury content of said separated solvent, (5) converting the insolubilized mercury to metallic mercury or chloride of mercury, and (6) returning said metallic mercury to a cathode of a mercury cathode brine electrolysis cell.

Claim 23

In an improved process for making elemental chlorine and sodium-mercury amalgam by the electrolysis of brine in a mercury cathode electrolysis cell wherein depleted brine is reconcentrated by contact with solid sodium chloride and returned to said electrolysis cell, said contact with sodium chloride resulting in the accumulation of insoluble impurities as saturator sludge, said sludge containing minor concentrations of mercury, separating said sludge from said brine for disposal outside the cell, and adding to the electrolysis cell metallic mercury in amount at least equal to the mercury retained by said saturator sludge; the improvement which comprises: recovering the mercury content of said sludge by sequentially: (1) acidifying said sludge with hydrochloric acid to a pH below 2.5, (2) leaching said sludge with aqueous hypochlorite solvent at a pH above 5, (3) separating said solvent from the leached sludge, (4) isolating the major part of the mercury content of said separated solvent, (5) converting the insolubilized mercury to metallic mercury or chloride of mercury, and (6) returning said metallic mercury to a cathode of a mercury cathode brine electrolysis cell.