For too long, the challenges of industrial combustion analysis have been seen as a series of expensive, high-stakes problems. The core task is straightforward: burn fuel as efficiently as possible while minimizing harmful emissions. But anyone who works in power generation from coal, oil, or gas, or petrochemicals knows the reality is far more complex. Fuel quality changes, and with it, you need to maintain the air-to-fuel ratio for a clean, efficient burn.
This constant adjustment is vital for two reasons: saving money and avoiding fines. In a world where fuel costs fluctuate and environmental regulations are getting stricter, every improvement in efficiency matters. The EPA and other agencies require continuous emissions monitoring, such as NOx (nitrogen oxides), with stringent uptime requirements. Failing to comply can mean significant penalties and operational shutdowns.
Many facilities use Selective Catalytic Reduction (SCR) or Selective Non-Catalytic Reduction (SNCR), commonly known as deNOx, to mitigate NHx emissions. This process involves injecting ammonia NH3 into the flue gas to convert NHx into harmless nitrogen (NH2) and water.
While effective against NHx, this introduces a significant, frustrating problem: ammonia slip - the excess unreacted NH3 that escapes the abatement process.
Ammonia itself is a regulated pollutant, meaning you solve one compliance issue only to create another.
Excess NH3 reacts to form corrosive ammonium salts that severely damage costly downstream equipment, such as air preheaters and catalytic converters.
The sticky nature of NH3 and the salt formation clog up pipes and sensors, leading to costly downtime and frequent, laborious repairs.
Overinjection of ammonia can contaminate fly ash, impacting its quality and usability.
For years, extractive sampling — the go-to method — has been the standard for emissions measurement. This technique pulls a hot gas sample from the stack, then cools it down and removes moisture before analysis.
Figure 1. A typical combustion process employing catalytic reduction for the abatement of ammonia emissions.
Industry requires a better solution that eliminates the need for a sample conditioning system and provides reliable data.
Tunable Diode Laser (TDL) Spectroscopy is a technology that measures gases directly inside the stack (in situ), eliminating the need to extract or condition a sample. TDL technology is the essential upgrade for reliable NH3 slip and CO/CO2 combustion trim control.
Technology | TDL Spectroscopy (in situ) | Extractive Sampling |
Measurement State | Hot/Wet (true process condition) | Cold/Dry (flawed measurement) |
Accuracy | High: No NH3 loss to condensate. | Low: Significant NH3 loss. |
Maintenance | Very low: No sample conditioning required. | Extremely high: Prone to clogging/corrosion. |
CEMS Uptime | High: >95% easy to meet. | Low: Frequent failures and repairs. |
While traditional cross-pipe TDL systems can struggle with dust loading, misalignment, and high purge gas consumption, a probe-style TDL analyzer offers a superior, robust solution:
Ultimately, the goal isn't just to buy a piece of useful equipment.
It's to invest in a solution that makes your daily work easier, your plant more efficient, and your operations more secure.
Dr. Tyler Schertz originally planned a career in pure chemistry, but his passion for instrumentation led him to become a leading voice in the process analytical industry. His unique ability to translate the complexities of molecular synthesis into reliable industrial measurements makes him an invaluable resource for customers. Whether he is exploring new TDL applications or sharing his expertise through technical presentations, Tyler’s mission is to make advanced gas analytics accessible, reliable, and efficient for the global market.
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