Optimizing mercury analysis in cement production to comply with strict air emission limits for mercury

Direct mercury analyzer at a cement plant

CUSTOMER

Heidelberg Materials Romania is a key player in the Romanian cement industry, operating under the global umbrella of Heidelberg Materials Group. At their Fieni Cement Plant, the laboratory team is responsible for ensuring the highest standards of environmental protection and regulatory compliance. The lab is equipped with advanced technologies that support both sustainability goals and strict quality control processes. Mercury emissions, in particular, are subject to stringent environmental regulation at both the local and European Union levels, especially under the Industrial Emissions Directive (IED). To meet these requirements, the lab must monitor mercury concentrations in a variety of incoming materials as well as conduct routine in-process checks to ensure environmental control throughout cement production.

CHALLENGE

The team at Heidelberg Materials Romania needed an efficient and accurate solution for monitoring mercury levels in both raw material feedstock and alternative fuels used in cement production. The company must comply with strict air emission limits for mercury, currently set at 0.05 mg/Nm³, and must also verify these emissions annually through third-party laboratory testing. Mercury concentrations can vary from as low as 0.01 ppm up to 10 ppm, depending on the type of sample. Previously, mercury analysis on raw materials and fuels was conducted entirely by external laboratories, creating significant limitations in terms of turnaround time and decision-making. This approach made it difficult to handle changes in mercury content of the materials for the production process. Furthermore, the cement plant relies on continuous emissions monitoring systems (EMS), but material-based mercury testing is still essential for environmental risk management. Heidelberg’s internal lab required a faster, reliable mercury analysis method that could support routine screening of fuels (coal, RDF, oil sludge, wastes), raw materials (such as limestone), and process-related samples, without the need for extensive chemical preparation or specialized technical staff.
From the customer voice:
“Mercury testing is performed not only on incoming fuels and raw materials but also at key stages during the process, helping the plant proactively manage environmental performance. Our in-house capability provided by the DMA-80 plays a crucial preventive role for us”
John David, Chemist @ Heidelberg

IMPLEMENTATION of DMA-80

After evaluating various technologies, they selected the DMA-80 Direct Mercury Analysis system. The decision was based on several key factors:
  • The ability to analyze both solid and liquid samples directly, without digestion or chemical pretreatment.
  • High precision and repeatability, even at trace-level Hg concentrations relevant to production inputs.
  • Full compliance with internationally recognized testing protocols, including EPA Method 7473, which the lab had already implemented for mercury determination by direct thermal decomposition, amalgamation, and AAS.
  • Low maintenance requirements made possible by a robust design and automated features.
  • A user-friendly interface and automated workflow, enabling the lab team to quickly integrate the instrument into daily operations without extensive retraining.
  • Milestone’s local representative provided full support during installation, method setup, and training.
  • The DMA-80 is now fully embedded in the lab’s routine. Mercury testing is performed not only on incoming fuels and raw materials but also at key stages during the process, helping the plant proactively manage environmental performance.

CONCLUSIONS

Since implementing the DMA-80 system for mercury analysis, Heidelberg Materials Romania has achieved several measurable improvements:
  • A significant reduction in analysis time, enabling faster decision-making and greater laboratory productivity.
  • Greater accuracy and repeatability in mercury determination, supporting both internal quality assurance and external regulatory reporting.
  • Avoid chemical reagents and digestion steps, resulting in low operational costs and safev lab conditions.
  • Minimized maintenance needs, which reduces downtime and improves instrument availability.
  • Ongoing technical support from Milestone’s local representative (Ronexprim), providing the lab with confidence and stability in their mercury analysis process.
While the plant’s mercury emissions are continuously monitored using EMS and verified annually by an external lab, the in-house capability provided by the DMA-80 plays a crucial preventive role. It allows Heidelberg to identify and address elevated mercury levels before they impact emissions, supporting the company’s commitment to sustainability, environmental protection, and production quality.

DMA-80 evo

Direct Mercury Analyzer for cement production
The DMA-80 mercury determination system can analyze any matrix, like fuels (coal, RDF, oil sludge, wastes), raw materials (such as limestone), and process-related samples, without the need for extensive chemical preparation in as few as 6 minutes in full compliance with EPA method 7473.
Discover DMA-80
DMA-80

Mercury analysis on raw materials and fuels

Download the complete Lab Profile
Since implementing the DMA-80, Heidelberg Materials Romania has achieved several measurable improvements, like a significant reduction in analysis time, enabling faster decision-making process and greater laboratory productivity
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heidelberg-lab-profile
Milestone Analytical
Milestone™ Srl
Via Fatebenefratelli 1/5 - 24010 Sorisole (BG) - Italy
Teléfono: +39 035.573857 | Fax: +39 035.575498
VAT n. IT01879330163 - Privacy Policy - Cookies - Sitemap
Acceso
Milestone Analytical
Milestone™ Srl
Via Fatebenefratelli 1/5 - 24010 Sorisole (BG) - Italy
Teléfono: +39 035.573857 | Fax: +39 035.575498
VAT n. IT01879330163
Privacy Policy
Cookies
Sitemap
Acceso