[curiouscat]

Easy, replace Ca(OH)2 with NaOH.

That's the baseline anyways. That'd be conceding defeat. Not yet.

Maybe from a Chemist's viewpoint this sounds silly? "If NaOH works why not use it?"  The motivation is more "applied"; costs might be a major saving. Even if the yields are a bit lower I might be able to accept that, factoring in the cheaper cost of Ca(OH)2 / more profitability in isolating and selling CaCl2 as opposed to NaCl.

Your result is about what I was expecting. I think the insolubility of the calcium salts is basically the source of your problems.

Not all of them. CaCl2 is very soluble like Borek indicated. Maybe if I can get purer Ca(OH)2 or add lesser of it there should't be as much left over insoluble Ca(OH)2 to form the emulsion?  The Chemistry seems a success; an emulsion might have Physical solutions. I'm not sure but optimistic.

Add HCl to make CaCl2 and separate.

That's an idea I like. Will try right away. Thanks!

[curiouscat]

An update:

Add HCl to make CaCl2 and separate.

That's an idea I like. Will try right away. Thanks!

Adding HCl to the emulsion turns out to be not-so-good. The emulsion does clear up but at the same time it seems to push the reaction in the reverse direction. Makes Halohydrin from Epoxide. So that's a no-go.

Have to think of other options now.

[discodermolide]

Try adding a smidgeon of n-octanol and see if the emulsion breaks.
Or add some celite and stir like hell.

[curiouscat]

Try adding a smidgeon of n-octanol and see if the emulsion breaks.
Or add some celite and stir like hell.

Aha! Never thought of either! Thanks! Will try.

[DrCMS]

What prices are you expecting for calcium hydroxide compared with sodium hydroxide?  Are you going to handle both as solids?  I'd always aim to handle hydroxides in solution so NaOH at 47-50% in bulk is much easier and safer (therefore cheaper) to handle than bags of a solid hydroxide even if the solid is cheaper per tonne.

[curiouscat]

Are you going to handle both as solids?  I'd always aim to handle hydroxides in solution so NaOH at 47-50% in bulk is much easier and safer (therefore cheaper) to handle than bags of a solid hydroxide even if the solid is cheaper per tonne.

Both options are open for lime. About NaOH I agree.  Yet, pretty sure that NaOH is always more expensive than Ca(OH)2 in either form.

[curiouscat]

Try adding a smidgeon of n-octanol and see if the emulsion breaks.

Had some handy and it works wonders. Thanks for the idea @disco.

Still trying to optimize the quantity though; first experiment we needed quite a lot of it. 

[discodermolide]

Well that is good news.