The Fastest Path to Accurate Gas Measurement in Harsh Industrial Environments

Industrial operators face increasing pressure to improve efficiency, reduce emissions, and maintain safe operations. Yet many gas measurement systems still rely on extractive sampling methods that introduce delays, require significant maintenance, and can struggle in challenging process conditions.

High temperatures, dust, corrosive gases, moisture, and pressure fluctuations often affect measurement reliability, leading to:

• Delayed process adjustments
• Higher fuel consumption
• Increased emissions
• Unplanned maintenance
• Reduced plant availability
• Safety risks

To overcome these challenges, many operators are turning to Tunable Diode Laser Spectroscopy (TDLS) technology.

TDLS enables direct, real-time gas measurement inside the process, delivering fast and accurate data without the need for complex sample conditioning systems.

TDLS (Tunable Diode Laser Spectroscopy) is a laser-based gas measurement technology that determines gas concentrations by analyzing how a specific gas absorbs light at a unique wavelength.
Because each gas molecule absorbs light differently, TDLS delivers highly selective measurements with minimal interference from other gases.
Unlike traditional analyzers, TDLS measures directly in the process stream and does not require direct sensor contact with the process gas.

✅ Real-time measurements
✅ Fast response times
✅ No sample conditioning systems
✅ Low maintenance requirements
✅ High reliability in harsh conditions
✅ Accurate measurements even in dusty or corrosive environments

While many analyzer technologies have their place, there are several applications where TDLS clearly offers significant advantages.

Challenge

Refineries, petrochemical plants, and power stations depend on efficient combustion to maximize throughput while minimizing fuel consumption and emissions.
Traditional extractive analyzers often measure gases after significant delays and require extensive maintenance.

TDLS can measure oxygen (O₂), carbon monoxide (CO), and methane (CH₄) directly in the combustion zone with response times of only a few seconds.

Operators can immediately optimize air-fuel ratios, leading to:

Reduced fuel usage
Lower CO and NOx emissions
Improved energy efficiency
Increased process safety

Example

A refinery operating multiple fired heaters can install a TDLS analyzer near the radiant section of the furnace to continuously monitor O₂ and CO levels and adjust combustion conditions in real time.

Challenge

Burner failures in furnaces or boilers can result in unstable combustion, energy losses, and potentially hazardous conditions.

TDLS can detect:

• – Methane (CH₄)
• – Carbon monoxide (CO)
• – Oxygen (O₂)

almost instantly, allowing operators to identify abnormal combustion conditions before they escalate.

Example

A power plant can use TDLS methane measurement to immediately identify burner flame-out situations and take corrective action.

Challenge

Selective Catalytic Reduction (SCR) systems are widely used to reduce NOx emissions. However, overdosing ammonia creates “ammonia slip,” resulting in environmental compliance issues and catalyst damage.

TDLS provides highly selective NH₃ measurement with fast response times, enabling optimized ammonia injection.

Benefits include:

• – Reduced ammonia consumption
• – Improved emissions compliance
• – Extended catalyst lifetime
• – Lower operating costs

Example

Waste-to-energy plants and power stations use TDLS to continuously monitor ammonia slip downstream of SCR systems.

Challenge

Carbon Capture, Utilization and Storage (CCUS) processes require accurate moisture monitoring to prevent corrosion, maintain product quality, and protect equipment.
Conventional measurement technologies can struggle with contamination and slow response.

TDLS offers low-level moisture measurements with excellent sensitivity and repeatability.

Example

A CO₂ transportation pipeline operator can use TDLS to ensure moisture remains below specified limits before compression and transport.

Challenge

Biomass and waste-to-energy combustion environments are notoriously difficult due to:

• High dust loading
• Variable fuel composition
• Corrosive gases
• Temperature fluctuations

Traditional analyzers often suffer from plugging and maintenance issues.

Because TDLS is a non-contact technology, it can operate reliably where conventional analyzers frequently struggle.

Example

A waste-to-energy facility can use TDLS to continuously optimize combustion and improve overall energy recovery.

Organizations increasingly choose TDLS because it helps solve some of the most common analyzer challenges:

Common Problem	TDLS Advantage
Slow analyzer response	Near real-time measurement
Sample system maintenance	No sample conditioning required
Dusty environments	Non-contact measurement
Corrosive gases	Minimal process exposure
Analyzer drift	Stable optical measurement
High OPEX	Lower maintenance costs
Safety concerns	Fast detection of abnormal conditions

As process industries pursue greater efficiency, safety, and sustainability, gas measurement technology becomes increasingly important.

TDLS provides a unique combination of speed, accuracy, reliability, and low maintenance that makes it particularly effective for:

• Combustion optimization
• Burner failure detection
• Ammonia slip monitoring
• Moisture measurement
• CCUS applications
• Biomass and waste-to-energy facilities
• Harsh industrial processes

For operators seeking accurate gas measurements where traditional technologies reach their limits, TDLS is often the most effective solution available today.

Explore real-world use cases, technical resources, and expert guidance from Yokogawa’s gas analysis specialists to see how TDLS can improve process performance, safety, and sustainability.

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