Title of Invention	A SENSING APPARATUS AND A METHOD OF SENSING A COMBUSTION PROCESS THEREWITH
Abstract	A sensing apparatus comprisess: diode laser (12) each having a select laser frequencies, a multiplexer optically coupled to the outputs of the diode lasers with the multiplexer being further optically coupled to a pitch side optical fiber. Multiplexed laser light is transmitted through the pitch side optical fiber to a pitch optic operatively associated with a process chamber which may be a combustion chamber or the boiler of a coal or gas fired power plant. The pitch optic is oriented to project multiplexed laser output through the process chamber. Also operatively oriented with the process chamber is a catch optic in optical communication with the pitch optic to receive the multiplexed laser output projected through the process chamber. The catch optic is optically coupled to an optical fiber which transmits the multiplexed laser output to a demultiplexer. The demultiplexer demultiplexes the laser light and optically couples the select lasing frequencies of light to a detector with the detector being sensitive to one of the select lasing frequencies.

Title of Invention

A SENSING APPARATUS AND A METHOD OF SENSING A COMBUSTION PROCESS THEREWITH

Abstract

A sensing apparatus comprisess: diode laser (12) each having a select laser frequencies, a multiplexer optically coupled to the outputs of the diode lasers with the multiplexer being further optically coupled to a pitch side optical fiber. Multiplexed laser light is transmitted through the pitch side optical fiber to a pitch optic operatively associated with a process chamber which may be a combustion chamber or the boiler of a coal or gas fired power plant. The pitch optic is oriented to project multiplexed laser output through the process chamber. Also operatively oriented with the process chamber is a catch optic in optical communication with the pitch optic to receive the multiplexed laser output projected through the process chamber. The catch optic is optically coupled to an optical fiber which transmits the multiplexed laser output to a demultiplexer. The demultiplexer demultiplexes the laser light and optically couples the select lasing frequencies of light to a detector with the detector being sensitive to one of the select lasing frequencies.

Full Text	WO 2004/090496 PCT/US2004/010048 METHOD AND APPARATUS FOR THE MONITORING AND CONTROL OF COMBUSTION TECHNICAL FIELD The present invention is directed tov/ard a method and apparatus for the monitoring and control of a combustion process, and more particularly toward the use of tunable diode laser absorption spectroscopy to monitor and control combustion processes. BACKGROUND ART A large percentage of the electrical power generated in the United States of America is created in coal combustion power plants. The bulk of worldwide electricity production similarly relies on coal as a primary energy source. It is likely that coal will remain a primary energy source in the foreseeable future given the long term environmental concerns with the storage of waste from nuclear energy generation operations, and the inefficiencies associated with solar powered electrical generation. In addition vast worldwide coal reserves exist sufficient for at least 200 years of energy production at current rates. However, there is and will continue to be a high demand to reduce the emissions of pollutants associated with coal fired electrical energy generation, and to increase the overall efficiency of the coal fired generation process. Traditionally, in power plants and other industrial combustion settings the efficiency of the combustion process and the level of pollution emission have been determined indirectly through measurements taken on extracted gas samples with techniques such as non-dispersive infrared (NDIR) photometry. Extractive sampling systems are not particularly well suited to closed loop control of a combustion process since a significant delay can be introduced between the time of gas extraction and the ultimate analysis. In addition, extractive processes generally result in a single point measurement which may or may not be representative of the actual concentration of the 1 WO 2004/090496 PCT/US2004/010048 measured species within what can be a highly variable and dynamic combustion process chamber. Laser based optical species sensors have recently been implemented to address the concerns associated with extraction measurement techniques. Laser based measurement techniques can be implemented in situ and offer the further advantage of high speed feedback suitable for dynamic process control. A particularly promising technique for measuring combustion gas composition, temperature and other combustion parameters is tunable diode laser absorption spectroscopy (TDLAS). TDLAS is typically implemented with diode lasers operating in the near-infrared and mid-infrared spectral regions. Suitable lasers have been extensively developed for use in the telecommunications industry and are, therefore, readily available for TDLAS applications. Various techniques of TDLAS which are more or less suitable for the sensing and control of combustion processes have been developed. Commonly known techniques are wavelength modulation spectroscopy, frequency modulation spectroscopy and direct absorption spectroscopy. Each of these techniques is based upon a predetermined relationship between the quantity and nature of laser light received by a detector after the light has been transmitted through a combustion process chamber and absorbed in specific spectral bands which are characteristic of the gases present in the process or combustion chamber. The absorption spectrum received by the detector is used to determine the quantity of the gas species under analysis plus associated combustion parameters such as temperature. For example, Von Drasek, et al., United States Patent Application Serial Number 2002/0031737A1, teaches a method and apparatus of using tunable diode lasers for the monitoring and/or control of high temperature processes. Von Drasek features the use of direct absorption spectroscopy to determine the relative concentration of numerous combustion species, temperature and other parameters. Calabro, United States Patent 2 WO 2004/090496 PCT/US2004/010048 Number 5,813,767, teaches a similar system for monitoring combustion and pollutants developed in a combustion chamber. Calabro utilizes an indirect spectroscopy technique wherein observed Doppler broadening of the shape of an absorption feature serves as the basis for temperature analysis. Teichert, Fernholz, and Ebert have extended the use of TDLAS as a known laboratory analysis technique to a workable field solution suitable for the sensing of certain combustion parameters within the boiler fireball of a Ml sized coal fired power plant. In their article, "Simultaneous in situ Measurement of CO, H2O, and Gas Temperature in a Full-Sized, Coal- Fired Power Plant by Near-Infrared Diode Lasers," {Applied Optics, 42(12):2043, 20 April 2003) the authors present a successful implementation of direct absorption spectroscopy at a coal fired power plant and discuss certain technical challenges resulting from the extremely large scale and violent nature of the coal burning process. In particular, typical coal fired power plants have combustion chamber diameters of 10-20 meters. The plants are fired by pulverized coal, which results in a combustion process which both obscures the transmission of laser light because of the high dust load and which is extremely luminous, hi addition, various strong disturbances are found under power plant combustion conditions. The overall transmission rate of light through the process chamber will fluctuate dramatically over time as a result of broadband absorption, scattering by particles or beam steering owing to refractive-index fluctuations. There is also intense thermal background radiation from the burning coal particles which can interfere with detector signals. The environment outside of the power plant boiler also makes the implementation of a TDLAS sensing or control system problematic. For example, any electronics, optics or other sensitive spectroscopy components must be positioned away from intense heat, or adequately shielded and cooled. Even though the implementation of a TDLAS system is extremely difficult under these conditions, TDLAS is particularly well suited to monitor and control a coal combustion 3 WO 2004/090496 PCT/IIS2004/010048 process. The present invention is directed to overcoming one or more of the TDLAS implementation problems discussed above. SUMMARY OF THE INVENTION One aspect of the invention is a sensing apparatus consisting of more than one diode laser having select lasing frequencies, a multiplexer optically coupled to the outputs of the diode lasers with the multiplexer being further optically coupled to a pitch side optical fiber. Multiplexed laser light is transmitted through the pitch side optical fiber to a pitch optic operatively associated with a process chamber which may be a combustion chamber or the boiler of a coal or gas fired power plant. The pitch optic is oriented to project multiplexed laser output through the process chamber. Also operatively oriented with the process chamber is a catch optic in optical communication with the pitch optic to receive the multiplexed laser output projected through the process chamber. As used herein, "coupled", "optically coupled" or "in optical communication with" is defined as a functional relationship between counterparts where light can pass from a first component to a second component either through or not through intermediate components or free space. The catch optic is optically coupled to an optical fiber which transmits the multiplexed laser output to a demultiplexer. The demultiplexer demultiplexes the laser light and optically couples the select lasing frequencies of light to a detector with the detector being sensitive to one of the select lasing frequencies. Optionally, the sensing apparatus may have each diode laser optically coupled to a distinct corresponding input optical fiber prior to the multiplexer and the detector optically coupled to an output fiber of the demultiplexer. The pitch side optical fiber may be a single mode fiber, and the catch side optical fiber may be a multimode fiber. Optionally, the sensing apparatus may further consist of a pitch side optical routing device optically coupled to the pitch side optical fiber and routing the multiplexed laser output to 4 WO 2004/090496 PCT/US2004/010048 more than one pair of pitch and catch optics operatively associated with the process chamber. The optical routing device may be an optical switch, an optical splitter, or other commonly available off the shelf telecommunications optical routing apparatus. Optionally, the sensing apparatus may further consist of a data processing system receiving input from the detector and employing commonly known laser spectroscopy techniques to determine a combustion parameter from the detector data. The sensing apparatus may also have means for affecting the combustion parameter based upon the output of the data processing system. For example, the sensing apparatus may provide for closed loop control of a combustion input such as air flow, fuel flow or catalyst or chemical agent addition which control is responsive to the data processing system in accordance with the combustion parameter determined by the data processing system. The sensing apparatus may utilize an echelle grating in the multiplexer or demultiplexer. Additional components of the multiplexer or demultiplexer may include an optical wave guide and a collimating focusing optic. The reflective echelle grating coupled to the collimating/focusing optic will typically have a groove spacing and blaze angle providing for the simultaneous demultiplexing of a plurality of ranges of widely spaced wavelengths of light. An appropriate echelle grating will typically be capable of multiplexing or demultiplexing wavelengths equal to or greater than 670 nm through wavelengths equal to or less than 5200 nm. To accomplish this, the echelle grating will operate at orders of detraction from the second order to at least the fourteenth order. Such an echelle grating will typically have a groove spacing of approximately 171.4 lines per mm and a blaze angle of approximately 52.75 degrees. Optionally, the sensing apparatus may have the multiplexer optically coupled to fewer than all of the diode lasers and further consist of an optical coupler coupled to the output of the multiplexer and the separate output of any unmultiplexed diode laser. In such an optional 5 WO 2004/090496 PCT/US2004/010048 embodiment, the optical coupler will optically communicate with the pitch optic through a select length of transmitting optical fiber. The length of the transmitting optical fiber may be selected to minimize mode noise. For example, the transmitting optical fiber may be implemented at a length of equal to or less than 3 meters, and be fabricated of Coming SMF 28 optical fiber which will assure that wavelengths less than 1240 nm, in particular 760 nm, do not become multi-modal during transmission through the transmitting optical fiber. The sensing apparatus may also consist of means to mechanically manipulate a section of the catch side optical fiber to minimize catch side mode noise. One example of an appropriate means to mechanically manipulate a section of the catch side optical fiber consists of a motor having a shaft parallel to the longitudinal axis of the catch side optical fiber which is attached to the fiber and provides a twisting motion around the longitudinal axis. The twisting motion may consist of a sweep through plus 360 degrees and minus 360 degrees at a rate of at least 10 Hz to effectively average the transmitted signal and thereby reduce catch side mode noise. Optionally, the sensing apparatus may further consist of a catch side alignment mechanism associated with the catch optic providing for the alignment of the catch optic with respect to the direction of the projection of the mutliplexed laser output. The alignment mechanism may increase the quantity of laser light received by the catch optic from the pitch optic and thereby coupled to the catch side optical fiber. The alignment mechanism may consist of an apparatus which allows the catch optic to tilt along a first axis and a second axis orthogonal to the first axis with both the first and second axes being substantially orthogonal to the direction of the projection of the multiplexed laser output. A stepper motor may be used to tilt the catch optic and a data processing system may be further associated with the catch side alignment mechanism and receive data from the detector related to the strength of the multiplexed laser output coupled to the detector and cause the catch side alignment 6 WO 2004/090496 PCT/US2004/010048 mechanism to align the catch optic. Alternatively, a separate alignment beam may be projected to the catch optic and used as a reference for alignment purposes. A similar alignment mechanism may be implemented on the pitch side of the sensing apparatus to provide for alignment of the pitch optic and adjustment of the direction of the projection of the multiplexed laser output. Another aspect of the present invention is a method of sensing a combustion process consisting of providing laser light at multiple select lasing frequencies, multiplexing the laser light, and transmitting the multiplexed laser light in a pitch side optical fiber to a process location. The process location may be a combustion chamber such as the boiler of a gas or coal fired power plant. After transmitting the multiplexed laser light to the process location, the method further consists of projecting the multiplexed laser light through a combustion process, receiving the multiplexed laser light in a catch side optical fiber, demultiplexing the multiplexed laser light and transmitting a frequency of the demultiplexed laser light to a detector. Optionally, the method may further consist of determining a combustion parameter from an output of the detector and controlling the combustion process in accordance with the determined combustion parameter. Another aspect of the invention is an echelle grating based diode laser spectroscopy gas sensing apparatus consisting of more than one diode laser having select lasing frequencies optically coupled to an input echelle grating having select line spacing and a select blaze angle providing for the multiplexing of laser light at the select lasing frequencies. The apparatus further consists of an optical fiber optically coupled to the output of the echelle grating and receiving multiplexed laser light from the echelle grating. In addition, a pitch optic is optically coupled to the distal end of the optical fiber with the pitch optic being operatively associated with a process chamber which can be a combustion chamber and with the pitch optic being further oriented to project laser light through the process chamber. The 7 WO 2004/090496 PCT/US2004/010048 apparatus further consists of an output echelle grating in optical communication with the pitch optic with the output echelle grating having a select groove spacing and a select blaze angle to provide for the demultiplexing of laser light at the select lasing frequencies. In addition, more than one detector sensitive at one of the select lasing frequencies is optically coupled to the output echelle grating. The apparatus of this aspect of the invention may further consist of a catch optic in optical communication with the pitch optic and in optical communication with the output echelle grating. Furthermore, one or more collimating optics may be optically coupled between the output of the echelle grating and a corresponding detector. The echelle grating of the diode laser spectroscopy gas sensing apparatus may have a groove spacing and blaze angle allowing the simultaneous (demultiplexing of a plurality of ranges of widely spaced wavelengths. An appropriate echelle grating can (de)multiplex optical channels having wavelengths equal to or greater than 670 nm through wavelengths equal to or less than 5200 nm. Such an echelle grating would operate from the second to the fourteenth order of refraction, and may have groove spacing of approximately 171.4 lines per mm and a blaze angle of approximately 52.75 degrees. Another aspect of the present invention is a method of sensing a combustion process consisting of providing laser light at multiple select lasing frequencies, multiplexing the laser light with an echelle grating, projecting the multiplexed laser light through a combustion process, demultiplexing the multiplexed laser light with an echelle grating and transmitting a frequency of demultiplexed laser light to a detector. This method may further consist of determining a combustion parameter from an output of the detector and controlling the combustion process in accordance with the determined combustion parameter. Another aspect of the present invention is a pitch side optical system for use in diode laser spectroscopy consisting of more than one diode laser having select lasing frequencies with each diode laser being coupled to an end of a distinct input optical fiber. The pitch side 8 WO 2004/090496 PCT/US2004/010048 optical system further consists of a multiplexer optically coupled to the other end of less than all of the input optical fibers with the multiplexer outputting multiplexed laser light to a pitch side optical fiber. Typically, the diode lasers and multiplexer will be housed in a climate controlled room situated remotely from the combustion process chamber. The pitch side optical system further consists of a coupler optically coupled to the far end of the pitch side optical fiber and the far end of an unmultiplexed input optical fiber with the coupler combining the multiplexed laser light and the unmultiplexed laser light and outputting the combined light to a transmission optical fiber. Typically, the coupler is located near the combustion process. The pitch side optical system further consists of a pitch optic coupled to the transmission optical fiber. Typically, all optical fibers used in the pitch side optical system are single mode optical fibers. The length of the transmitting optical fiber may be selected to minimize optical noise. In particular, if laser light of relatively shorter wavelengths, for example 760 nm, had been multiplexed with laser light of relatively longer wavelengths, for example 1240 nm - 5200 nm, and such a multiplexed beam had been transmitted in a suitable commercially available telecommunications optical fiber which did not exhibit a high rate of bending and other transmission losses over the entire transmitted spectrum, the relatively shorter wavelengths may have become multimodal over an extended distance. Thus, the transmission fiber length may be selected to minimize the creation of mode noise. For example, a transmission fiber length of 3 meters or less, with the transmission fiber being Coming SMF 28 optical fiber, can transmit laser light with a wavelength of 760 nm from the coupler to the pitch optic without the introduction of significant multi-modal behavior. Another aspect of the present invention is a catch side optical system for use in diode laser spectroscopy consisting of a catch side optic optically coupled to a catch side multimode optical fiber and means to mechanically manipulate a section of the catch side multimode 9 WO 2004/090496 PCT/US2004/010048 optical fiber to minimize catch side mode noise. The mechanical manipulation may consist of twisting the catch side multimode optical fiber around its longitudinal axis. The means to mechanically manipulate the section of the catch side multimode optical fiber in the above fashion may consist of a motor associated with the catch side multimode optical fiber such that a section of fiber is held fast relative to a shaft position of the motor and the motor shaft is repetitively swept through +360 degrees and -360 degrees of motion. The frequency of the motor shaft sweep may be at least 10 Hz to enable effective averaging of the transmitted signal and thereby reduce the effect of catch side mode noise. Another aspect of the present invention is a diode laser spectroscopy gas sensing apparatus having a diode laser with a select lasing frequency, a pitch optic coupled to the diode laser with the pitch optic being operatively associated with a process chamber and oriented to project laser light along a projection beam through the process chamber. This aspect of the invention additionally includes a catch optic in optical communication with the pitch optic to receive the laser light projected through the process chamber and an optical fiber optically coupled to the catch optic. Li addition, the catch optic is operatively associated with a catch side alignment mechanism which provides for Hie alignment of the catch optic with respect to the projection beam to increase a quantity of laser light received by the catch optic from the pitch optic and coupled to the optical fiber and a detector sensitive to the select lasing frequency optically coupled to the optical fiber. The catch side alignment mechanism may consist of means to tilt the catch optic along a first axis and a second axis orthogonal to the first axis with both the first and second axes being approximately orthogonal to the projection beam. The means to tilt the catch optic may be a stepper motor. The diode laser spectroscopy gas sensing apparatus may also consist of an alignment beam of light projected by the pitch optic and received by the catch optic and a data processing system operatively associated with the detector and catch side alignment mechanism receiving data 10 WO 2004/090496 PCT/US2004/010048 from the detector related to the strength of the alignment beam and further causing the catch side alignment mechanism to align the catch side optic with the projection beam to maximize the strength of the alignment beam coupled to the detector. The diode laser spectroscopy gas sensing apparatus of this aspect of the invention may further consist of a pitch side alignment mechanism providing for alignment of the pitch optic and adjustment of the direction of the projection beam. The pitch optic may be implemented substantially as described above for the catch optic. Another aspect of the present invention is a method of aligning a diode laser spectroscopy gas sensing optical system. The method consists of providing an alignment beam of light, projecting the alignment beam through a process chamber, receiving the alignment beam with a catch optic, the catch optic being operatively associated with the process chamber. The method further consists of optically coupling the alignment beam from the catch optic to a detector through an optical fiber and determining the strength of the alignment beam coupled from the catch optic to the optical fiber. In addition, the method consists of aligning the catch optic to maximize the strength of the alignment beam coupled from the catch optic to the optical fiber. The method of aligning a diode laser spectroscopy gas sensing optical system may further consist of tilting the catch optic along a first axis and a second axis orthogonal to the first axis. Alternatively, the alignment beam may be projected by a pitch optic and the pitch optic may be aligned as well to further maximize the strength of the alignment beam coupled from the catch optic to the optical fiber. Another aspect of the present invention is a method of sensing NO in a combustion process with tunable diode laser absorption spectroscopy. The NO sensing method consists of providing laser light at a wavelength of approximately 670 nm, transmitting the laser light in a pitch side optical fiber to a combustion location, projecting the laser light through a combustion process and receiving the laser light in a catch side optical fiber. The method 11 WO 2004/090496 PCT/US2004/010048 farther consists of transmitting the laser light in the catch side optical fiber to a detector and generating a signal from the detector related to the laser light transmitted to the detector. In addition, the method consists of calculating a NO2 concentration from the signal and determining a NO concentration from the calculated NO2 concentration. The NO sensing method may be implemented with the provision of laser light at a wavelength of 670 run by producing laser light with a wavelength of approximately 1340 nm with a diode laser and frequency-doubling the laser light in a quasi-phase matched periodically polled waveguide. A suitable waveguide is a quasi-phase matched periodically polled lithium Niobate waveguide. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic diagram of a sensing apparatus of the present invention. Fig. 2 is a schematic diagram of a sensing apparatus of the present invention featuring remotely located components optically coupled to components near the combustion chamber. Fig. 3 is an illustration of an aspect of the present invention featuring multiple sensing grids. Fig. 4 is an illustration of a prior art single beam gas detection apparatus. Fig. 5 is an illustration of a prior art multiple beam gas detection apparatus. Fig. 6 is an illustration of the use of an echelle grating in the present invention. Fig. 7 is an illustration of an echelle grating based diode laser spectroscopy gas sensing apparatus of the present invention. Fig. 8 is an illustration of a pitch side optical system suitable for minimizing mode noise. Fig. 9 is an illustration of a fiber coupled gas sensing apparatus. Fig. 10 is an illustration of light lost between pitch and catch optics. 12 WO 2004/090496 PCT/US2004/010048 Fig. 11 is an illustration of the angular acceptance cone of a fiber optic system. Fig. 12 is a schematic diagram of an alignment mechanism of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT SENSING APPARATUS As shown in Fig. 1 an embodiment of the present invention is a sensing apparatus 10 suitable for the sensing, monitoring and control of a combustion process. The sensing apparatus 10 performs tunable diode laser absorption spectroscopy (TDLAS) using laser light from a series of tunable diode lasers 12 lasing at select frequencies in the near-infrared or mid-infrared spectrum. The output of each tunable diode laser 12 is coupled to an individual optical fiber which may be a single mode optical fiber 14 and routed to a multiplexer 16. As used herein, "coupled", "optically coupled" or "in optical communication with" is defined as a functional relationship between counterparts where light can pass from a first component to a second component either through or not through intermediate components or free space. Within the multiplexer 16 the laser light of some or all of the frequencies generated is multiplexed to form a multiplexed probe beam having multiple select frequencies. The multiplexed probe beam is coupled to a pitch side optical fiber 18 and transmitted to a pitch optic 20 or collimator operatively associated with a process chamber which, in Figure 1, is shown as a combustion chamber 22. The pitch optic 20 is oriented to project the multiplexed probe beam through the combustion chamber 22. Across the combustion chamber 22 in optical communication with the pitch optic 20 is a catch optic 24. The catch optic 24 is preferably substantially opposite the pitch optic 20 and is operatively associated with the combustion chamber 22. The catch optic 24 is positioned and oriented to receive the multiplexed probe beam projected through the combustion chamber 22. The catch optic 24 is optically coupled to a catch side optical 13 WO 2004/090496 PCT/US2004/010048 fiber 26 which transmits the portion of the multiplexed probe beam which is received by the catch optic 24 to a demultiplexer 28. Within the demultiplexer 28 the portion of the multiplexed probe beam received by the catch optic 24 is demultiplexed and each wavelength of demultiplexed laser light is coupled to an output optical fiber 30. Each output optical fiber 30 in turn is optically coupled to a detector 32, which typically is a photodetector sensitive to one of the select frequencies of laser light generated and multiplexed to form the probe beam. The detectors 32 generate an electrical signal based upon the nature and quantity of light transmitted to the detector 32 at the detector frequency. The electrical signal from each detector 32 is typically digitized and analyzed in data processing system 34. As discussed in detail below, the digitized and analyzed data can be used to sense physical parameters within the process chamber including but not limited to the concentrations of various gas species and the combustion temperature within the combustion chamber 22. The data processing system 34 can further be used to send signals through a feedback loop 36 to combustion control apparatus 38 and thereby actively control select process parameters. In the case of a combustion process, the process parameters controlled can include fuel (e.g., pulverized coal) feed rates; oxygen feed rates and catalyst or chemical agent addition rates. The use of fiber optic coupling of the electronic and optical components on both the pitch and catch sides of the sensing apparatus 10 allows delicate and temperature sensitive apparatus such as the tunable diode lasers 12, detectors 32 and data processing system 34 to be located in a control room having a stable operating environment. Thus, only the relatively robust pitch and catch optics 20, 24 need be situated near the hostile environment of the combustion chamber 22. Figure 2 schematically depicts the overall component placement of a fiber coupled, multiplexed sensing system 40. The sensing system 40 generally consists of a system rack 42, a breakout box 44, a transmitter head 46 having pitch optics 48, a receiver head having catch optics 52 and connecting optical fibers. The system rack 42 is preferably located in a 14 WO 2004/090496 PCT/US2004/010048 remote control room situated a distance, for example one kilometer, from the combustion chamber 54. The control room typically will have a moderate environment. The system rack 42 contains the lasers 56, detectors 58, wavelength multiplexers 60 and wavelength demultiplexers 62. The system rack 42 also houses the system electronics and control software (not shown on Fig. 2). The system rack 42 may optionally house an alignment light source 64. The optical fibers connecting the system rack 42 with the breakout box 44 are typically standard single-mode telecom optical fiber. This type of fiber is inexpensive, readily available, low-loss and allows the laser light to be directed to various off-the-shelf telecom components to manipulate the light, such as optical switches, splitters, and wavelength division multiplexers. Without optical fiber coupling, the laser light would have to be directed through free space all the way to the combustion chamber 54, which would be very difficult to implement or, alternatively, sensitive electronic and optical components would have to be situated in close proximity to the combustion chamber 54. Also shown on Fig. 2 is a breakout box 44. The breakout box 44 is a ruggedized enclosure located close to the boiler. The breakout box 44 contains optical switches, splitters and couplers (collectively 66) which may be used as discussed below to direct the optical signals to multiple transmitter-receiver head pairs. A third group of system components as shown on Fig 2 are the transmitter and receiver heads 46, 50. The optics and electronics in the transmitter and receiver heads 46, 50 must convert the light in the fiber 68 into a collimated beam, direct the beam accurately through the combustion chamber 54, capture the beam on the far side of the combustion chamber 54 and couple the beam into the fiber 70. The choice of optics to accomplish this is determined by the transmission distance, the turbulence of the combustion zone, its effect on the transmitted beam's quality, and the core size of the fiber 70. Preferably, the fiber core 15 WO 2004/090496 PCT/US2004/010048 diameter is 50 microns, which is a compromise: a larger core will capture more of the laser light but also much more of the background light. Fiber coupling on the catch (receiver) side has several advantages. In particular, only light in the same location as the laser light and traveling in the same direction is focused into the fiber 70. This drastically reduces the amount of background light that is sensed. In an alternative embodiment, light may be captured into one of several receiver fibers and an optical switch or other optical routing device can select light from one fiber for routing to the detectors 58. The use of fiber coupling at the catch side requires that the alignment tolerances of both the transmitter and receiver optics be precisely maintained (less than 0.5 milliradian for both the transmitter and receiver pointing). The alignment system discussed below makes it feasible to meet these tolerances in a harsh power plant environment. Preferably, both the pitch and catch optics 48, 52 are custom-designed and aberration-corrected for wavelengths from 660 nm to 1650 nm so that multiple laser signals can be efficiently transmitted and received at the same time. SENSING APPARATUS WITH MULTIPLE SETS OF SENSING OPTICS Referring again to Fig 1, an embodiment is depicted schematically which features more than one set of pitch optics 20 and catch optics 24 associated with a single combustion chamber 22. The multiplexed probe beam can be routed by a routing device which, as is shown in Fig. 1, may be an optical switch 72 to each set of pitch optics 20. Suitable routing devices include optical switches which may be implemented to route the probe beam with minimal attenuation to each set of pitch/catch optics in a predetermined sequence or an optical splitter which simultaneously routes a fractional portion of the multiplexed probe beam to each set of optics. 16 WO 2004/090496 PCT/US2004/010048 A similar optical routing device which, in Figure 1, is shown as a multimode optical switch 74 can be employed on the catch side of the system to route the portion of the multiplexed probe beam received by each catch optic 24 to the catch side demultiplexer 28. Although the embodiment depicted in Figure 1 shows only two sets of pitch and catch optics, the system can employ any number of pitch and catch optical sets. The use of fiber coupling and a (de)multiplexed probe beam on both the pitch and catch sides of the system allows multiple sets of pitch and catch optics to be implemented with one set of lasers 12 and detectors 32. Without the incorporation of optical multiplexing techniques, separate sets of lasers, detectors and fiber cables, all requiring calibration, would be needed for each transmitter/receiver pair. As discussed in detail below, multiple transmitter/receiver pairs allow the implementation of one or more two dimensional sensing grids over the entire combustion chamber 22 or elsewhere, such as for sensing a downstream gas process. A schematic illustration of two highly simplified sensing grids, a fireball sensing grid 76 and a downstream sensing grid 78 are shown in Fig. 3. In addition, the fiber-coupled nature of the present invention allows readily available telecommunications components to be used to positive effect. For instance, a fiber-optics switch can be used to route the multiplexed probe beam to different locations for measurement. 1 X N optical switches with N up to 8 are readily available as off-the-shelf components from a variety of suppliers. Switches with N up to 16 can be custom ordered. A switch and multiple pairs of pitch and catch optics can be used for serial probing of a gas species at different locations throughout the combustion chamber. For situations in which averaged results are sufficient, serial probing of different beam paths is acceptable. However, certain applications require instantaneous probing of an entire sensing grid. For example, certain combustion process flows exhibits high-frequency fluctuations, or the flow may only exist for a short period of time, e.g. shock tubes or tunnels. In such a case a 1 X N 17 WO 2004/090496 PCT/US2004/0J0048 splitter may be used to divide the probe beam into N branches each of which occupies a different position on the grid. Since the entire grid is illuminated simultaneously, a two dimensional analysis can be generated very quickly. However, simultaneous two dimensional analysis may require that each component on the catch side be reproduced for each beam path including demultiplexers, detectors, electronics such as A/D cards and, to some extent, computers. Thus, embodiments featuring switches or splitters facilitate somewhat coarse tomographic reconstruction of two-dimensional cross sections of the probed region. Using diode lasers to do tomography of gas concentrations is a known technique, however significant additional benefit is achieved under the present invention as a result of the use of a probe beam which is wavelength multiplexed. The wavelength multiplexed beam allows for the simultaneous spectroscopic analysis of more than one absorption line. Thus TDLAS techniques which rely on more than one line, such as temperature determination, as discussed in detail below, can be performed across the entire sensing grid. Both temperature and gas species concentrations can be mapped in this way. SPECIFIC APPLICATION OF TOMOGRAPHY IN SCR AND SNCR A specific application of coarse tomography as described above is schematically illustrated in Fig. 3 and concerns the optimization of ammonia injection in SCRs (selective catalytic reduction) and SNCRs (selective non-catalytic reduction) for the reduction of NOX from coal or gas fired power generation boiler effluent, m this application, a matrix of ammonia or urea injectors 80 are placed in the flow of boiler effluent. In order to minimize the NOX concentration, an excess of ammonia (or urea) may be added to the effluent. NOX is a heavily regulated and highly undesirable family of air pollutants. The added ammonia chemically reduces the NOX and forms harmless nitrogen gas and water as products. 18 WO 2004/090496 PCT/US2004/010048 However, the amount of excess ammonia (or urea) added must be minimized because these chemicals themselves are toxic air pollutants and quite expensive. Typically an excess concentration of power plant combustion effluent is not uniform, nor is it temporally stable. In addition, one or more of the ammonia injectors may foul at any given time causing a local decrease in the ammonia concentration leading to a local bleed through in the NOX concentration. With the ability to monitor the spatial concentration of ammonia or NOX with a downstream TDLAS grid 78 sensing as described above, the present invention allows non-uniform ammonia distributions to be detected and mitigated. Thus, optimization of the ammonia injection grid 76 with two-dimensional species concentrations and individual control over injectors allows the optimization of the SCR/SNCR process. The detectors and ammonia injectors may be linked to a data processing system providing automated feedback control of the ammonia injectors. An optimized ammonia slip detection system, such as the one described herein, should preferably include the ability to monitor NOX concentration. NOX includes both NO and NO2. Unfortunately, robust NIR diode lasers can only access the second NO overtone transition occurring in the 1.7-1.8-micron region. This transition is too weak to detect NO given the relatively low concentrations present in most effluent flows. Therefore it is not practical to directly monitor NO concentration. However, NO2 is formed by the same processes that form NO. These processes, known in the power generation industries as the thermal NOX process produce both NO and NO2 with NO accounting for approximately 95% of the total NOX concentration and NO2 accounting for the remaining 5 % under typical conditions. The exact ratio typically depends upon temperature and the oxidizing potential of the environment. As discussed above, this technique allows for determination of the temperature of the sampled gas as well. However, it is expected that the NO and NO2 19 WO 2004/090496 PCT/US2004/010048 concentrations will track each other. Thus NO2 can be used as a surrogate analysis species for NO. The present invention provides the ability to monitor NO2 at a wavelength of 670 run. This wavelength is produced using a 1340 nni distributed-feedback (DFB) laser frequency-doubled in a phase-matched periodically poled lithium Niobate waveguide. Even though the NO2 concentration is only 5% the NO concentration, the NO2 absorption strength is orders of magnitude stronger. Thus, NO2 can be detected readily at the concentrations present in boilers to facilitate optimization of NOX reduction processes. TUNABLE DIODE LASER ABSORPTION SPECTROSCOPY The present invention performs TDLAS using techniques known to those skilled in the art of laser spectroscopy. Generally, TDLAS is performed by the transmission of laser light through a target environment, followed by the detection of the absorption of the laser light at specific wavelengths, due to target gases such as carbon monoxide or oxygen. Spectral analysis of the detected light allows identification of the type and quantity of gas along the laser path. The details of direct absorption spectroscopy are discussed in Teichert, Fernholz, and Ebert, "Simultaneous in situ Measurement of CO, H2O, and Gas Temperature in a Full-Sized, Coal-Fired Power Plant by Near-Infrared Diode Lasers," {Applied Optics, 42(12):2043, 20 April 2003), which reference is incorporated herein in its entirety. The non- contact nature of laser absorption spectroscopy makes it well-suited for harsh environments such as the combustion zone of a coal-fired power plant, or flammable or toxic environments where other probes cannot be used. The use of laser light provides the high brightness necessary to get detectible transmission in the presence of severe attenuation (typically greater than 99.9% loss of light) that may be seen in some of these environments. To better withstand the harsh conditions of the target applications, the laser light may be brought in to the target environment through armored optical fiber. 20 WO 2004/090496 PCT/US2004/010048 Effective sensing of temperature or multiple combustion process component gasses requires the performance of TDLAS with multiple widely spaced frequencies of laser light. The frequencies selected must match the absorption lines of the transitions being monitored. For example, as discussed above it is useful to monitor NO2 at a wavelength of 670 run to approximate emission NO concentrations. It is also quite useful to monitor oxygen, water (temperature), and carbon monoxide in a coal-fired utility boiler. Suitable absorption lines, and thus suitable lasing frequencies can be selected based upon an assumption that the laser probe path length through a combustion chamber is equal to 10 meters and that the mole fraction of each species is CO (1%), O2 (4%), CO2 (10%), and H2O (10%). For frequency selection purposes, the process temperature can be assumed to be 1800 K which is slightly higher than what is typically observed in a coal fired plant, but the cushion serves as a safety factor in the calculations. For example, three water absorption lines can be selected for TDLAS that meet the following criteria: 1. Lower state energy of ~ 1000, 2000, and 3000 cm"1 respectively 2. Provides a convenient absorbance of around 0.1 - 0.4 that, in turn, leads to approximately 20% beam absorption on resonance. 3. The optimum situation is to utilize transitions in the 1250 to 1650 nm region where inexpensive, high power, DFB diode telecommunications lasers are available. 4. The transitions must be well separated to allow for easy multiplexing. 5. The selected wavelength must be efficiently diffracted by the existing (de)multiplexer gratings. Suitable water lines occur at the following wavelengths: 21 WO 2004/090496 PCT/US2004/010048 US04/10048 Page left intentionally blank 22 WO 2004/090496 PCT/US2004/010048 TABLE 1 Wavelength (nm) Wavenumber (cm"1) Lower State Energy (cm"1) Grating Order Absoprtion at 1800 K and 10 M UNP Grating Efficiency (model) 1349.0849 7412.432 1806.67 6.87 19.7% 81% 1376.4507 7265.062 3381.662 6.73 28.1% 77% 1394.5305 7170.872 1045.058 6.65 6.8 % 72% No interference from any other combustion gases is anticipated. The most likely species to interfere, CO2 was modeled and there are no strong, interfering lines in the 1.3- 1.4 micron region. Similarly, a suitable carbon monoxide line can be selected based on the work of Ebert referenced and incorporated above. A suitable carbon monoxide line is found at 1559.562 nm using the R(24) line in a coal-fired utility boiler. Selection of this line avoids interference from water and carbon dioxide. Known gratings are quite efficient in this wavelength region since it is in the optical communications C band. The absorbance at this wavelength is expected to be 0.7%. In addition, oxygen can be measured at 760.0932 nm. The preferred (de)multiplexing grating efficiency calculates to be only 40% in this region, however suitable laser power should be available for reasonable measurement efficiency. As discussed herein, the use of fiber coupling on both the pitch and catch sides of a TDLAS sensing apparatus requires critical alignment of the pitch and catch optics. Active alignment is preferably accomplished with a select alignment wavelength. One possible alignment wavelength is 660 nm because high power (45 mW) diodes are available at this frequency and 660 nm would be near the peak of 14th order grating operation. Other alignment wavelengths may be determined to be equally or more suitable. 23 WO 2004/090496 PCT/US2004/0I0048 In summary, a reasonable set of wavelengths selected for multiplexing to a probe beam for TDLAS as embodied in the present invention are as shown in Table 2. It should be noted that this wavelength set is for one embodiment of a TDLAS sensing apparatus suitable for the sensing and control of a coal fired power plant. Other wavelength sets can be equally suitable. TABLE 2 Purpose Wavelength (nm) Alignment 660 O2 b-a band 760.0932 H2O (moderate temp, line) 1349.0849 H2O (high temp, line) 1376.4507 H2O (low temp, line) 1394.5305 CO R(24) of (2,0) overtone 1559.562 SPECIFIC BENEFITS OF TDLAS USING MULTIPLEXED BEAM A particular advantage of TDLAS with a wavelength-multiplexed probe beam is increased accuracy of temperature measurements. In order to make accurate concentration measurements with TDLAS, the temperature of the monitored gas must be known. The strength of a molecular absorption is a function of temperature. Thus, to convert the amplitude of an absorption feature to concentration, the temperature must be known. Certain previous attempts to measure the concentration of combustion species such as CO suffer from insufficiently accurate temperature measurements leading to errors in quantification. This is particularly true for diode laser based ammonia slip monitors that have traditionally not incorporated temperature measurement at all. hi the sensing system of the present invention, temperature may be determined by measuring the ratio of the intensity of two or more 24 WO 2004/090496 PCT/US2004/010048 molecular water lines. The ratio of the integrated intensity of two lines is a function of temperature only (assuming constant total system pressure). Thus, in principle, two lines provide an accurate temperature. However, in the case of a non-uniform temperature distribution (as is typically found within an industrial combustion process), two lines do not suffice to determine the temperature distribution. In such a non-uniform temperature distribution, two lines can only determine a "path-averaged" temperature. In contrast, measuring the integrated amplitude of more than two lines (of the same species) allows temperature non-uniformity to be probed. An example of this technique has been demonstrated using oxygen as the probe molecule by Sanders, Wang, Jeffries and Hanson in "Applied Optics" (vol. 40, num. 24, 20 August 2001), which reference is incorporated herein in its entirety. The preferred technique relies on the fact that the distribution of peak intensities measured along a line of sight is not the same for a path at an average temperature of 500 K, for example, as it is where one half of the path is at 300 K and the other half is at 700 K. In addition to the benefit of more accurate temperature measurement, the use of a multiplexed probe beam can allow for the simultaneous monitoring of more than one combustion gas species, allowing for more refined control over the combustion process. ECHELLE GRATING BASED APPARATUS The present invention benefits from the use of relatively inexpensive and commonly available optical components designed for use in the telecommunications industry. The telecommunications apparatus serve well to fiber couple the pitch and catch sides of the system. Telecommunications applications typically use optical multiplexers which, accept multiple light beams at wavelengths which are relatively close spaced and separated by a constant value (such as 0.8 nm). The light beams are then generally coupled onto a single- 25 WO 2004/090496 PCT/US2004/010048 mode optical fiber. Demultiplexers perform the inverse process. Telecommunications equipment is typically designed to perform at wavelengths between 1520 and 1620 run, with the Optical C-band, 1528 - 1563 nm, being the most utilized. In the case of (de)multiplexerss the same physical device may be used for either multiplexing or demultiplexing, depending upon the direction of the light which passes through it. Consequently, the term "multiplexer" or "mux" as used herein will be understood to include both multiplexing and demultiplexing functions. Optical multiplexers may use any of several technologies to accomplish the mux/demux function. However, echelle grating-based muxes are advantageous in that they may be incorporated into a very simple and compact design. Echelle gratings are relatively course diffraction gratings that operate in orders other than the first order with blaze angles typically greater than 45 degrees. The course line spacing on the grating combined with high order operation results in a large angular dispersion that allows the device to be compact. Some telecommunications applications may require that other wavelengths well outside of the C band be simultaneously serviced by optical multiplexers (for instance 1310 nm). Additionally, applications outside the telecommunications field such as the TDLAS sensing and control apparatus of the present invention may require the multiplexing of laser light at widely separated wavelengths, such as separations of approximately 100s of nm. An example illustrative of the benefits of an echelle grating based multiplexed sensing apparatus is developed in Figs. 4-7. Fig. 4 illustrates a gas sensing apparatus 82 in which light 84 is directed through a flame 86 from one side. A sensor 88 on the other side of the flame detects the transmitted light and determines how much light is absorbed by the gasses in the flame 86. In the device illustrated in Fig. 4, only a single beam of light is passed through the flame 86. The wavelength of the light may be chosen to correspond to the absorption wavelength of a particular gas. Alternatively, the light may be a white light which, after passing through 26 WO 2004/090496 PCT/US2004/010048 the flame 86, is spit into various wavelengths, such as by a prism. The absorption at each wavelength of interest can then be measured. In a slightly more sophisticated prior art alternative, a device such as that illustrated in Fig. 5 may be used to pass a number n of separate beams of light 90A - 90n through the flame 92. Each beam of light 90A - 90n is at a different wavelength of interest and sensors 94A - 94n on the other side of the flame 92 measure the absorption at each wavelength, indicating relative amounts of selected gases of interest. There are several drawbacks to using multiple separate beams. First, access to the flame may be limited and attempting to project the multiple beams through the limited space may be awkward, if not impossible. Second, there is typically turbulence in the flame as well as pockets of non-uniformity. The multiple beams, even if very closely spaced, may not pass through the same sampling space and therefore not generate consistent or comparable results. Finally, the projection and sensing optics and detectors are more complex and costly in a multiple-beam apparatus compared to those in a single-beam apparatus. The echelle grating multiplexer based sensing device of the present invention has significant advantages over the prior art. An echelle grating provides unusual flexibility by being able to operate in orders other than the first order with blaze angles typically greater than 45 degrees. For instance, the Zolo Technologies, Inc. Zmux™ is optimized to operate in a Littrow configuration in the 6th order at 1545 nm with a mechanically ruled grating having a line spacing of 171.4 lines/mm and a blaze angle of 52.75 degrees. The grating equation for a Littrow mount is: mX = 2dsinGb (1) 27 WO 2004/090496 PCT/US2004/010048 where m is the order, X is the wavelength, d is the spacing between rulings, and 9b is the blaze angle. For a given grating, mX is a constant. For the Zmux grating referenced above, mX = 6(1.545) = 9.27 microns. Such a grating provides optimum efficiency for 1.545 microns in 6th order. However, the grating also provides very high efficiency for other orders as well. For instance, the 7th order occurs at 9.27/7 = 1.32 microns. Thus, a grating such as the Zmux can simultaneously multiplex C band light as well as 1310 nm light with high efficiency. Fig. 6 illustrates an echelle grating 96 multiplexing light 98A - 98n to be collimated by a collimator 100 into a single beam 102. Of particular relevance to the present invention are applications outside of the telecommunications field for multiplexing laser light at widely separated wavelengths, often over 100s of nm. In applications such as the present TDLAS based gas-sensing apparatus, it is critical for all wavelength components of a probe beam to sample the same region of space and many wavelengths may be necessary to detect a single species or to detect multiple species. For these applications, echelle grating-based mux/demuxes provide a unique solution. For example, the echelle based de/multiplexer described above is capable of muxing a substantial wavelength region about the central wavelengths given in Table 3 below where each wavelength region corresponds to a different grating order. 28 WO 2(104/090496 PCT/US2004/010048 TABLE 3 Order Central Wavelength (microns) Approximate Wavelength Range (microns) 2 4.63 4.40-4.80 3 3.09 2.90-3.30 4 2.32 2.15-2.40 5 1.85 1.70-1.95 6 1.55 1.50-1.57 7 1.32 1.24-1.39 Higher orders up to and beyond the fourteenth order may also be multiplexed with correspondingly narrower wavelength ranges. It is noteworthy that single mode transmission for all of these wavelengths is not possible in readily available optical fiber. One aspect of a gas-sensing apparatus 104 of the present invention is schematically illustrated in Fig. 7. This aspect highlights the advantages of TDLAS with a multiplexed laser output has over the prior art embodiments discussed above. In the Fig. 7 embodiment, a number n of laser sources 106A - 106n operating at widely separated wavelengths are multiplexed by an echelle grating 108 onto a single optical fiber 110. The light from the single fiber 110 is collimated by a collimator or pitch optic 112 and passed through the sample 114 (such as a flame) to be analyzed. After passing through the sample 114, the light is demultiplexed by another echelle grating 116. The transmitted light at each wavelength is detected by a corresponding photodetector 118A - 118n. The lasers 106A - 106n are tuned over a narrow spectral region (such as 1-2 urn) and absorption by the sample 114 is monitored over each spectral region scanned. In this way, the gas under test can be fully identified and quantified. Other 29 WO 2004/090496 PCT/US2004/010048 parameters such as gas temperature and pressure may be measured as well. In addition to combustion sensing, widely separated wavelength echelle grating mux/dermix technology may enable medical devices to measure gases in exhaled breath and homeland defense devices to detect chemical warfare agents. Other applications are possible in the fields of display and microscopic vision technology by using the echelle based muxes and red/green/blue coupler devices. MODE NOISE The optical train of the TDLAS system of the present invention, and similar implementations which require a signal multiplexed from widely spaced wavelengths presents many design challenges due to the opposing design requirements of the reduction of mode noise and high efficiency light collection. Mode noise is defined herein as a change in the signal level of detected light that results from non-uniform time and wavelength varying light distribution in the core of a fiber used to collect and transport the light to and from the process chamber being measured. In a multimode fiber, different modes propagate at different velocities due to refractive index variations. The intensity distribution in the fiber is then a speckle pattern resulting from interference of all the propagating modes that have undergone different effective path lengths. If all light in the speckle pattern is collected and detected, then constructive and destructive interference cancel exactly and the total transmitted power does not depend on wavelength or fiber length. If clipping, vignetting or other loss is introduced, the exact cancellation fails and the detected power changes with wavelength and/or time. A general expression for the detected power after a length, z, of fiber is: P = Po + Sjj Cjj EiEjCos[(27w0Anijz)/c + A 30 WO 2004/090496 PCT/US2004/010048 where Po = wavelength independent average power E; = amplitude of light in the ith transverse mode cy = overlap integral between the ith and jth transverse mode Ally = refractive index difference between ith and jth modes A(j)y = phase shift between ith and jth modes due to temperature and stress For an orthonormal set of modes and no loss, cy = 0. However, with any beam clipping or vignetting or any other mode dependent loss will cause some cy ?O. This will lead to ripples in the average transmitted power. For a typical graded-index fiber with a 50 micron core, the total index change, An, is ~1%, but most modes spend the bulk of transmission time close to the fiber core center, and therefore, Any approximately 135 modes, which is sufficiently coarse to produce prominent mode noise during a wavelength scan given reasonably achievable beam clipping levels. As a concrete modal noise example, one may consider the simplest possible system that exhibits mode noise: a rectangular waveguide supporting only the lowest mode in one dimension and only the two lowest modes in the orthogonal dimension: Lowest mode: Ei = Ei° [exp i(kz - ©t)]cos 7tx/2a Next mode: E2 = E20 [exp i(kz - cot)]sin 7ix/a The intensity at a point z along the fiber is: I(x) = \|Ei + E2\|2 and the total power is P= jEi + E2\|2dx (3) 31 WO 2004/090496 PCT/US2004/010048 where the integral must include the effects of clipping and vignetting. In the absence of clipping, P~ Ei2 + E22 and there is no wavelength dependence. Adding clipping amounts to changing the limits of the integral. It can be shown that clipping results in an additional term ~ EiEicosA(\|> where A If single-mode fiber could be used in the catch side optical train of the present invention, mode noise would not be an issue. However, multimode fiber must typically be used in the catch side optical train of the present invention for two reasons. First, after traversing the measurement volume (a combustion chamber with a measurement path in excess of 10 meters), the initially single-mode (Gaussian spatial distribution) beam is significantly degraded in quality. Thus, the coupling efficiency of this severely distorted beam into single-mode fiber would be veiy poor. This is an unacceptable situation since the beam is attenuated by 3 - 4 orders of magnitude when passing through the measurement volume primarily due to scattering and obscuration by soot and fly ash. The additional attenuation resulting from using single-mode fiber would preclude measurement. Second, refractive beam steering effects in the fireball cause the position and pointing of the beam to be unstable. Given these effects, it would be difficult to "hit" the core of a single-mode fiber with any regularity. On the other hand, the core of a multimode fiber presents at least 25 times the target cross-sectional area of a single-mode fiber. Thus, the effects of beam steering can be significantly reduced. In addition, since the coupling efficiency into multimode fiber is independent of the spatial mode of the light, the poor beam quality obtained after passing through the fireball is not an issue. However, mode dependent losses occurring in the multi-mode fiber train are a significant design challenge. The light distribution emanating from the core of a multimode fiber exhibits a random speckle pattern, i.e. a random pattern of light and dark areas caused 32 WO 2004/090496 PCT/US2004/010048 by constructive and destructive interference between different modes of the fiber. If the speckle pattern was totally invariant as a function of time and wavelength, it would not present a problem. However, slow variations in the speckle pattern particularly as a function of wavelength can cause mode noise if the beam is clipped anywhere in the multirnode catch side optical train as described above. This clipping is impossible to avoid; it can only be reduced. Therefore, additional measures to reduce mode noise must be implemented to improve the detection sensitivity of the system. There are several ways in which to mitigate mode noise. From equation 2 above, mode noise may be reduced by: 1) reduce mode dependent losses, i.e. reduce clipping thereby keeping the cy small 2) reduce z, thereby increasing the period of the model noise to be much greater than the absorption lines of interest 3) reduce Any by using low dispersion fiber 4) scramble the modes; but not all mode scrambling techniques are equally effective, as is described below. Preferably, the catch optics of the present invention are designed and implemented to incorporate all of the above in order to reduce modal noise. The optics are designed such that any beam clipping should occur at a low level given near perfect alignment of the system. Efforts should be made to keep the length of multimode fiber to a minimum; however, for some applications z must be long in order to have the control electronics in an environmentally controlled area. The value of Any may be reduced by using premium low- dispersion multimode fiber. In addition, excellent results may be obtained by scrambling the modes by mechanical manipulation of a catch side multimode fiber. 33 WO 2004/090496 PCT/US2004/010(148 The speckle pattern exhibited in a multimode fiber varies as a Sanction of lime and wavelength and also as a function of the mechanical position of the fiber. Flexing the fiber and manipulating it in specific ways can cause the speckle pattern to change. If these mechanical manipulations are performed continuously, over a period of time, the spatial distribution of light emanating from the fiber averages to a relatively uniform pattern. The crux of the scrambler of the present invention is to reduce mode noise by mechanically manipulating multi-mode fiber to produce, on average, a uniform light beam that does not produce mode noise when subjected to inevitable low-level beam clipping. Some specific modes of fiber manipulation are more effective at reducing mode noise than others. In particular, twisting the fiber about its longitudinal (z) axis relative to some other point on the fiber causes the speckle pattern to change. In particular, the dominant change obtained is a rotation of the speckle pattern around the z-axis. Of interest is the fact that the pattern does not rotate as far around the axis as the fiber is mechanically rotated. A secondary effect is that the actual light distribution is somewhat altered by the rotation. The rotation of the speckle pattern is not due to stress-induced refractive index changes in the fiber, although this may explain small changes in the speckle intensity pattern. Rather, the rotation is due to the light's inability to completely follow the waveguide as it is manipulated in a torsional motion. This observation can be used to virtually eliminate mode noise caused by the use of multimode fiber for the catch side optical train. A highly preferred embodiment of the present invention uses a hollow shaft motor through which the multi-mode fiber is placed and fastened. A remote section of fiber is held fast relative to the shaft position of the motor, and the motor is repetitively swept through +360 degrees and then -360 degrees of motion. The frequency of this motion preferably is greater than or equal to 10 Hertz to enable effective 34 WO 2004/090496 PCT/US2004/010048 averaging of the transmitted signal, and significantly reduce the effect of catch sids mode noise. The pitch side optical train of the present invention also presents a significant design challenge due to the necessity of producing a single-mode beam for all wavelengths to be transmitted through the measurement region. If single-mode fiber could be used throughout the pitch side optical train, mode noise would not be an issue. However, fiber only operates as a single-mode waveguide over a limited wavelength window. Beyond the short wavelength cutoff for a particular fiber, light can be transported through the fiber in several higher order spatial modes. These higher order modes will interfere to produce a speckle pattern when the light exits the fiber. The speckle pattern is time and wavelength-varying. Even a small amount of beam clipping then gives rise to noise in the measurement. On the contrary, if a fiber is selected that has a single-mode cutoff that matches the shortest wavelength that needs to be transmitted, the longer wavelengths will suffer a substantial loss when coupled into the fiber and the fiber will exhibit extensive bending losses for the longer wavelengths. This problem can be acute in the fiber coupled, wavelength multiplexed TDLAS sensing and control device of the present invention due to the need to multiplex wavelengths as long as 1.67 microns with wavelengths as short as 760 nm or 670 nm. There is no known single commercially available fiber that will provide single mode operation, high coupling efficiency and low bending losses for such a broad range of wavelengths. Photonic crystal fiber may in the future provide a solution to this dilemma, but Photonic crystal fiber technology is currently in its infancy. As shown in Fig. 8, the current invention alleviates the problem of multiplexing and pitching light in a single mode beam from 670 nm or 760 nm to 1.67 microns by utilizing a very short transmission section of multimode fiber 120 that does not allow the higher order 35 WO 2004/090496 PCT/US2004/010048 spatial modes for a wavelength shorter than the single mode cutoff to develop. Referring to equation 2 above, if the length, L, of multi-mode fiber is short, then mode noise will be minimized. In this case, for example, if 760 run light is coupled to a short section of single mode fiber with a cutoff wavelength of 1280 nm (e.g. Corning SMF 28), the 760 nm light remains single-mode for at least a few meters. Therefore a solution to pitch side mode noise is to couple the 760 nm light into a fiber which is single mode for wavelengths longer than 1280 nm but could be multimode for 760 nm, with only a short distance to go before it is collimated to be transmitted through the measurement zone. A schematic diagram of such a system is shown in Fig. 8 and Fig. 2. Refemng first to Fig. 8, multiple diode laser sources 120 lasing at widely spaced lasing frequencies are coupled to discrete single mode optical fibers 122 A - 122n. The diode lasers lasing at wavelengths between 1349 nm and 1670 nm are multiplexed with multiplexer 124. The output of multiplexer 124 is coupled to a pitch side fiber optic 126 having suitable dimensions for transmitting light with wavelengths ranging from 1349 nm -1670 ;nm, both without substantial transmission losses and without the introduction of mode noise:. A suitable fiber optic for these wavelengths is Corning SMF28. However, the 760 nm input, if multiplexed and coupled to an SMF28 optical fiber would, after transmission over a relatively short distance, become multimodal. Accordingly, the output of the 760 nm laser is coupled to a fiber which is single mode for wavelengths less than 1280 nm such as SMF750. The laser light transmitted in the input fiber 122n and the multiplexed laser light transmitted in the pitch side optical fiber 126 can be coupled nearby the pitch optic 128. The coupler 130 and pitch optic 128 are preferably optically connected by a short length of transmission optical fiber 132 with the transmission optical fiber 132 being selected to transmit all of the coupled and multiplexed wavelengths without significant loss. A suitable transmission optical fiber for the system depicted in Fig. 8 would be Corning SMF28. Provided that the transmission 36 WO 2004/090496 PCT/US2004/010048 optical fiber is relatively short, the 760 run laser light coupled to the transmission optical fiber 132 will not exhibit multimodal behavior. For the system and fibers depicted in Fig. 8, it has been determined that the transmission optical fiber must be kept to a length of 3 meters or less to avoid the introduction of significant multimodal noise. A similar system is shown in Fig. 2 where coupler 136 receives input from both a 760 nm diode laser and a multiplexed beam from diode lasers having substantially longer wavelengths. ALIGNMENT SYSTEM Preferably, the sensing system of the present invention incorporates an auto alignment feature that allows the pitch and catch optics to maintain optimal alignment even though they are bolted on to a boiler or other hostile process chamber which is, itself, subject to movement from thermal effects, wind and vibration. In a highly preferred embodiment of the present system, both the pitch and catch optics are mounted on feedback-controlled tip/tilt stages. The requirement that both pitch and catch optics be mounted on tip/tilt stages results from the fact that the sensor is totally fiber-coupled. Thus, multiplexed light is launched across the measurement region by a collimating pitch optic attached directly to an input fiber, and the catch optic couples the transmitted light directly into an output fiber that typically is a multimode fiber. Accordingly, the catch optic must be oriented so that it is collinear with the beam emanating from the pitch optics. This is necessary so that the focused transmitted beam will arrive within the acceptance cone of the multimode catch fiber. In order to discriminate transmitted laser light from intense background light (for example, from the flames in a coal furnace), the field of view and focus of the detector can be limited to sense only light with the same direction and position as the input laser light. This may be done conveniently by focusing detected light into an optical fiber coupled to a 37 WO 2004/090496 PCT/US2004/010048 suitable detector. The basic optical system design of an embodiment of the present invention is shown schematically in Fig. 9. The transmitter 136 of Fig. 7 consists of a pitch optic 138 or collimator such as a collimating lens of one or more than one layer and associated mounting and alignment structures and electronics. Similarly, the receiver 140 of Fig. 7 consists of a catch optic 142 or collimator of similar or varied construction from the pitch optic and associated mounting and alignment electronics. The efficiency and background discrimination of a transmitter-receiver pair are tied to alignment tolerance. For highest efficiency and discrimination, the alignment tolerances for both the transmitter and receiver are severe. The transmitter must be pointed accurately enough so that most of the transmitted light strikes the clear aperture of the catch optic 146, as indicated in Fig. 10. For a typical system, this amounts to a 1 cm tolerance over a typical transmission distance of 10 meters, or 1 milliradian. (With target distances between 5 and 30 meters and launched spot sizes between 1 and 3 cm, diffraction is a small contribution.) As is graphically illustrated in Fig. 11, the receiver's angular acceptance is determined by the fiber core 148 diameter divided by the catch optic 150 focal length. A shorter focal length will increase the angular acceptance, but the receiver clear aperture becomes correspondingly smaller. A compromise having adequate clear aperture and angular acceptance is to use a 50 mm focal length lens and a 50 micrometer core fiber. This results in a 2 cm clear aperture and a 1-milliradian cone of angular acceptance. A preferred alignment system must therefore position two optics to point at each other with tolerances of 1 milliradian in both tip and tilt, for a total of four degrees of freedom. These four degrees of freedom might possibly be accomplished by rough alignment of one side followed by a four-dimensional alignment (tip, tilt, and lateral position in x and y) of the other side, but this assumes that large lateral motions are permissible. Since access; ports for target environments may be as small as 1 inch, this is potentially a problematic solution. 38 WO 2004/090496 PCT/US2004/010048 Alternatively, active pointing alignment at both ends can ensure proper alignment when limited space is available for lateral movement. The critical alignment of the pitch and catch optics must be maintained in a harsh and variable environment. Vibration, wind loading, temperature change and other structural shifts may all lead to misalignments, as will mechanical creep in the transmitter and receiver optomechanics. Misalignment can also be expected after periodic maintenance, when the transmitter and receiver heads are removed for cleaning and then re-mounted. Ideally, the optical system of the present invention will be able to maintain its 1 milliradian optical alignment in the face of system misalignments that could approach 50 milliradians. The alignment system should also retain position during power outages and tolerate total loss of signal, and be turned off without losing alignment. Finally, the system itself must preferably be ragged enough to function continuously for an extended period of time in an exposed, industrial environment. Fig. 12 schematically illustrates an embodiment of alignable pitch or catch optics. The transmitter and receiver are similar in design: the transmitter generates a collimated beam of laser light from light emerging from an optical fiber, and the receiver captures a collimated beam of laser light and focuses it into a fiber. (It is possible to send light backward through this optical system, and most of the elements of the transmitter and receiver are identical.) The transmitter and receiver optics may be mounted in NEMA-4 enclosures to protect them from the environment. The following description applies to either the: transmitter or receiver module. As shown in Fig. 10, the pre-collimated fiber/lens pair 152 is attached to a kinematic tilt stage 154 positioned to allow tip and tilt perpendicular to the optical axis. Two direct- drive stepper motors 156 accomplish tip and tilt. These motors are controlled by computer via an Ethernet or similar connection. This connection may be through optical fiber in order to 39 WO 2004/090496 PCT/US2004/010048 avoid electrical interference. The stepper motors 156 hold their position when power is removed, so the optical alignment is unaffected by electrical power outages. During periodic or continuous system alignment, the control computer monitors the amount of laser light that is transmitted and detected. Preferably, a discrete alignment wavelength may be provided for continuous or periodic alignment proceedings such as the visible light source 64 of Fig. 3. Any misalignment will reduce this detected signal. In auto- alignment mode, the computer measures the detected signal, directs one of the two stepper motors to move a small amount in one direction, then re-measures the detected signal. If the signal increases, then the computer directs the stepper motor to move again in the same direction until the signal does not increase. The computer then directs the other stepper motor to move along the orthogonal axis to maximize the detected signal, then repeats the whole process for the other sensor head. As the detected signal increases, the detector amplifier gain automatically decreases so that the auto-alignment process proceeds over several decades of signal size. The auto-alignment system can function with detected powers from nanowatts to milliwatts. This "hill-climbing" algorithm is able to align the system after near-total loss of signal, in the presence of substantial noise, and is tolerant of beam blockages, power outages, mechanical shocks and other disturbances that could cause other alignment systems to misalign to the limits of the control electronics. All that is required for auto-alignment is a finite signal with a global maximum in position space. Depending on specific installation conditions, auto-alignment may occur periodically at set intervals such as every hour or as needed after an extended period such as days of operation. The control computer may monitor the detected signal and auto-align only when the signal drops below a pre-set threshold. 40 WO 2004/090496 PCT/US2004/010048 The transmitter and receiver modules may incorporate several other features useful for industrial applications. Optional sensors may detect when the modules are moved out of position for cleaning or maintenance, and all lasers are turned off for safety. As shown on Fig. 10, All electrical and optical connections may made through a hinge 158 so that all such connections are undisturbed by maintenance operations. The enclosure 160 protects the sensitive internal optics from contaminants, and is preferable hosable. The hinge range of motion may be restricted to avoid operator injury. Preferably, each sensor head will require less than 10 watts of input electrical power during auto-alignment, and less than 0.1 watt after auto-alignment is complete. Alternate designs may be suitable for different applications. Considerable size and weight reduction are possible if NEMA-4 enclosure rating is not required. Different transmission distances may allow optics of different focal length and clear aperture to optimize the captured signal. As an alternative to the stepper motor-driven tilt stage described above to control pointing by moving the entire fiber-lens assembly, the fiber may be moved laterally relative to the lens to effect the same pointing change while moving a much smaller mass. Different electromechanics such as piezoelectric elements or voice coils may also be used to increase the speed of the auto-alignment system. In addition to the alignment concerns discussed above, the specific choice of pitch and catch optics can affect the performance of the TDLAS sensing system of the present invention in several ways: (1) Signal strength coupled to the detectors depends on pitch/catch efficiency. (2) The amount of undesirable background emission coupled to the detectors depends on catch optics etendue. 41 WO 2004/090496 PCT/US2004/010048 (3) The effects of few-mode noise at 760 nm are very sensitive to the pitclii/catch configuration. (4) The noise characteristics (small but more steady or larger with wild swings) are expected to depend on the launched beam size. A larger launch beam is preferable. (5) The system misalignment sensitivity is a direct function of pitch and catch focal lengths and associated fiber sizes. A very simplistic picture of a typical coal fired power plant combustion zone can be adopted for optical component selection analysis. The purpose of such analysis is to focus on the general effects on a laser beam passing through the fireball with as little knowledge of the fireball details as possible. Traversing the fireball has three effects on a light beam: (1) Soot particles absorb some of the light. (2) Large-angle refraction or scattering prevents some of the light from reaching the catch optic. (3) Light passes through numerous small thermal gradients and is thus steered randomly but still reaches the catch optic. Only the third category of light is available for collection. Assuming that a typical ray of light undergoes multiple refracting events while traversing the fireball, the direction of the ray follows a random path, and can drift away from its initial direction. If the ray is part of a larger beam composed of other rays that undergo similar but not identical drifts, then the effect of the fireball on the beam causes four distinct types of changes: 42 WO 2004/090496 PCT/US2004/010048 (1) Change in the overall direction of the entire beam (2) Change in the position of the centroid of the beam (3) Change in the beam size (4) Change in beam divergence/wavefront flatness These four types of changes are parameters which include all the major effects on the beam that will affect collection efficiency, without regard for the physics leading to these effects. If the directions of the rays of light in the fireball are undergoing random drift then the ray directions may diffuse away from the initial (nominally optimum) direction according to a standard diffusion dependence. However, the distance of a ray of light from the original axis depends on its prior directions. Thus, for a given amount of rms beam steering, determined by the details of the fireball, a directly proportional amount of beam offset can be expected. If a laser beam traversing the fireball is blown up to several times its original size then the same relationship will hold between the final beam size and final beam divergence. Light collection efficiency can be estimated if we know the angle, location and beam size of the light incident on the catch optics. The estimate assumes simple ray optics, flat-top intensities and a simple estimate the amount of light incident on the catch optic that is within the fiber numerical aperture NA and which is boresighted to strike the core of the fiber. The end result is a "hill" in offset-angle space. Assuming optimum alignment, collection efficiency is close to the top of the hill but may be rapidly moving over and around the hill as beam angle and position fluctuate. Preferably, the collection efficiency lull will be both as tall and as broad as possible. Several points about the hill are worth noting: 43 WO 2004/090496 PC17US2004/010048 (1) The peak height of the collection efficiency hill (for zero beam offset and tilt) is proportional to the square of the catch optic etendue (focal length times NA) unless the catch optic is large enough to capture the entire incident beam, at which point the catch efficiency is 100%. (2) The hill is elliptical, and changing the catch focal length makes one ax::s longer and the other shorter. (3) The fluctuation in light collection efficiency due to beam jitter is a noise source. Based upon the foregoing analysis techniques, the signal to noise ratio of different pitch/catch combinations may be compared. Assuming that the multiplicative noisie is the same, different catch optics differ in final performance only if the fireball background noise or detector noise are dominant. The objects of the invention have been fully realized through the embodiments disclosed herein. Those skilled in the art will appreciate that the various aspects of the invention may be achieved through different embodiments without departing from the essential function of the invention. The particular embodiments are illustrative and not meant to limit the scope of the invention as set forth in the following claims. 44 1. A sensing apparatus comprising: more than one diode laser each having a select lasing frequency; a multiplexer optically coupled to more than one of the diode lasers, the multiplexer outputting a multiplexed laser output, the multiplexed laser output being optically coupled to a proximal end of a pitch side optical fiber; a pitch optic optically coupled to a distal end of the pitch side optical fiber, the pitch optic being operatively associated with a combustion process and oriented to project the multiplexed laser output through the combustion process; a catch optic operatively associated with the combustion process in optical communication with the pitch optic to receive the multiplexed laser output projected through the combustion process; a catch side optical fiber optically coupled to the catch optic at a proximal end; a demultiplexer optically coupled to a distal end of the catch side optical fiber, the demultiplexer demultiplexing laser light of each of the select lasing frequencies; and a detector optically coupled with the demultiplexer, the detector being sensitive to one of the select lasing frequencies. 2. The sensing apparatus of claim 1 further comprising a data processing system receiving input from the detector and determining a combustion parameter. 3. The sensing apparatus of claims 1 through 2 further comprising means for affecting the combustion parameter operatively associated with the data processing system. 4. The sensing apparatus of claims 1 through 3 further comprising a plurality of detectors optically coupled with the de-multiplexer, each detector being sensitive to one of the select lasing frequencies. 45" AMENDED PAGE 5. The sensing apparatus of claims 1 through 4 wherein one of the multiplexer and demultiplexer comprises an echelle grating. 6. The sensing apparatus of claims 1 through 5 wherein the multiplexer is optically coupled to fewer than all of the diode lasers and further comprising an optical coupler optically coupled to the distal end of the pitch side optical fiber and a distal end of an un-multiplexed input fiber, the optical coupler optically coupling multiplexed laser light from the pitch side optical fiber and un-multiplexed laser light from the un-multiplexed input optical fiber, the optical coupler being in optical communication with the pitch optic. 7. The sensing apparatus of claims 1 through 6 further comprising means to mechanically manipulate a section of the catch side multimode optical fiber to minimize catch side mode noise. 8. The sensing apparatus of claim 1 through 7 further comprising a catch side alignment mechanism operatively associated with the catch optic providing for the alignment of the catch optic with respect to a direction of the projection of the multiplexed laser output to increase a quantity of laser light coupled to the catch side optical fiber. 9. The sensing apparatus of claim 1 through 8 further comprising a pitch side alignment mechanism providing for alignment of the pitch optic and adjustment of the direction of the projection of the multiplexed laser output. 10. A method of sensing a combustion process comprising: providing laser light at multiple select lasing frequencies; multiplexing the laser light; transmitting the multiplexed laser light in a pitch side optical fiber to a process location; projecting the multiplexed laser light through a combustion process; receiving the multiplexed laser light in a catch side optical fiber; demultiplexing the multiplexed laser light; and transmitting a frequency of demultiplexed laser light to a detector. 46 AMENDED FAGE 11. The method of claim 10 further comprising determining a combustion parameter from an output of the detector. 12. The method of claim 10 through 11 further comprising controlling the combustion process in accordance with the determined combustion parameter. AMENDED PAGE 47 A sensing apparatus consisting of more than one diode laser having select lasing frequencies, a multiplexer optically coupled to the outputs of the diode lasers with the multiplexer being further optically coupled to a pitch side optical fiber. Multiplexed laser light is transmitted through the pitch side optical fiber to a pitch optic operatively associated with a process chamber which may be a combustion chamber or the boiler of a coal or gas fired power plant. The pitch optic is oriented to project multiplexed laser output through the process chamber. Also operatively oriented with the process chamber is a catch optic in optical communication with the pitch optic to receive the multiplexed laser output projected through the process chamber. The catch optic is optically coupled to an optical fiber which transmits the multiplexed laser output to a demultiplexer. The demultiplexer demultiplexes the laser light and optically couples the select lasing frequencies of light to a detector with the detector being sensitive to one of the select lasing frequencies.

Full Text

WO 2004/090496 PCT/US2004/010048
METHOD AND APPARATUS FOR THE MONITORING AND CONTROL OF
COMBUSTION
TECHNICAL FIELD
The present invention is directed tov/ard a method and apparatus for the monitoring
and control of a combustion process, and more particularly toward the use of tunable diode
laser absorption spectroscopy to monitor and control combustion processes.
BACKGROUND ART
A large percentage of the electrical power generated in the United States of America
is created in coal combustion power plants. The bulk of worldwide electricity production
similarly relies on coal as a primary energy source. It is likely that coal will remain a primary
energy source in the foreseeable future given the long term environmental concerns with the
storage of waste from nuclear energy generation operations, and the inefficiencies associated
with solar powered electrical generation. In addition vast worldwide coal reserves exist
sufficient for at least 200 years of energy production at current rates.
However, there is and will continue to be a high demand to reduce the emissions of
pollutants associated with coal fired electrical energy generation, and to increase the overall
efficiency of the coal fired generation process. Traditionally, in power plants and other
industrial combustion settings the efficiency of the combustion process and the level of
pollution emission have been determined indirectly through measurements taken on extracted
gas samples with techniques such as non-dispersive infrared (NDIR) photometry. Extractive
sampling systems are not particularly well suited to closed loop control of a combustion
process since a significant delay can be introduced between the time of gas extraction and the
ultimate analysis. In addition, extractive processes generally result in a single point
measurement which may or may not be representative of the actual concentration of the
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measured species within what can be a highly variable and dynamic combustion process
chamber.
Laser based optical species sensors have recently been implemented to address the
concerns associated with extraction measurement techniques. Laser based measurement
techniques can be implemented in situ and offer the further advantage of high speed feedback
suitable for dynamic process control. A particularly promising technique for measuring
combustion gas composition, temperature and other combustion parameters is tunable diode
laser absorption spectroscopy (TDLAS). TDLAS is typically implemented with diode lasers
operating in the near-infrared and mid-infrared spectral regions. Suitable lasers have been
extensively developed for use in the telecommunications industry and are, therefore, readily
available for TDLAS applications. Various techniques of TDLAS which are more or less
suitable for the sensing and control of combustion processes have been developed.
Commonly known techniques are wavelength modulation spectroscopy, frequency
modulation spectroscopy and direct absorption spectroscopy. Each of these techniques is
based upon a predetermined relationship between the quantity and nature of laser light
received by a detector after the light has been transmitted through a combustion process
chamber and absorbed in specific spectral bands which are characteristic of the gases present
in the process or combustion chamber. The absorption spectrum received by the detector is
used to determine the quantity of the gas species under analysis plus associated combustion
parameters such as temperature.
For example, Von Drasek, et al., United States Patent Application Serial Number
2002/0031737A1, teaches a method and apparatus of using tunable diode lasers for the
monitoring and/or control of high temperature processes. Von Drasek features the use of
direct absorption spectroscopy to determine the relative concentration of numerous
combustion species, temperature and other parameters. Calabro, United States Patent
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Number 5,813,767, teaches a similar system for monitoring combustion and pollutants
developed in a combustion chamber. Calabro utilizes an indirect spectroscopy technique
wherein observed Doppler broadening of the shape of an absorption feature serves as the
basis for temperature analysis.
Teichert, Fernholz, and Ebert have extended the use of TDLAS as a known laboratory
analysis technique to a workable field solution suitable for the sensing of certain combustion
parameters within the boiler fireball of a Ml sized coal fired power plant. In their article,
"Simultaneous in situ Measurement of CO, H2O, and Gas Temperature in a Full-Sized, Coal-
Fired Power Plant by Near-Infrared Diode Lasers," {Applied Optics, 42(12):2043, 20 April
2003) the authors present a successful implementation of direct absorption spectroscopy at a
coal fired power plant and discuss certain technical challenges resulting from the extremely
large scale and violent nature of the coal burning process. In particular, typical coal fired
power plants have combustion chamber diameters of 10-20 meters. The plants are fired by
pulverized coal, which results in a combustion process which both obscures the transmission
of laser light because of the high dust load and which is extremely luminous, hi addition,
various strong disturbances are found under power plant combustion conditions. The overall
transmission rate of light through the process chamber will fluctuate dramatically over time
as a result of broadband absorption, scattering by particles or beam steering owing to
refractive-index fluctuations. There is also intense thermal background radiation from the
burning coal particles which can interfere with detector signals. The environment outside of
the power plant boiler also makes the implementation of a TDLAS sensing or control system
problematic. For example, any electronics, optics or other sensitive spectroscopy
components must be positioned away from intense heat, or adequately shielded and cooled.
Even though the implementation of a TDLAS system is extremely difficult under these
conditions, TDLAS is particularly well suited to monitor and control a coal combustion
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process. The present invention is directed to overcoming one or more of the TDLAS
implementation problems discussed above.
SUMMARY OF THE INVENTION
One aspect of the invention is a sensing apparatus consisting of more than one diode
laser having select lasing frequencies, a multiplexer optically coupled to the outputs of the
diode lasers with the multiplexer being further optically coupled to a pitch side optical fiber.
Multiplexed laser light is transmitted through the pitch side optical fiber to a pitch optic
operatively associated with a process chamber which may be a combustion chamber or the
boiler of a coal or gas fired power plant. The pitch optic is oriented to project multiplexed
laser output through the process chamber. Also operatively oriented with the process
chamber is a catch optic in optical communication with the pitch optic to receive the
multiplexed laser output projected through the process chamber. As used herein, "coupled",
"optically coupled" or "in optical communication with" is defined as a functional relationship
between counterparts where light can pass from a first component to a second component
either through or not through intermediate components or free space. The catch optic is
optically coupled to an optical fiber which transmits the multiplexed laser output to a
demultiplexer. The demultiplexer demultiplexes the laser light and optically couples the
select lasing frequencies of light to a detector with the detector being sensitive to one of the
select lasing frequencies. Optionally, the sensing apparatus may have each diode laser
optically coupled to a distinct corresponding input optical fiber prior to the multiplexer and
the detector optically coupled to an output fiber of the demultiplexer. The pitch side optical
fiber may be a single mode fiber, and the catch side optical fiber may be a multimode fiber.
Optionally, the sensing apparatus may further consist of a pitch side optical routing device
optically coupled to the pitch side optical fiber and routing the multiplexed laser output to
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more than one pair of pitch and catch optics operatively associated with the process chamber.
The optical routing device may be an optical switch, an optical splitter, or other commonly
available off the shelf telecommunications optical routing apparatus. Optionally, the sensing
apparatus may further consist of a data processing system receiving input from the detector
and employing commonly known laser spectroscopy techniques to determine a combustion
parameter from the detector data. The sensing apparatus may also have means for affecting
the combustion parameter based upon the output of the data processing system. For example,
the sensing apparatus may provide for closed loop control of a combustion input such as air
flow, fuel flow or catalyst or chemical agent addition which control is responsive to the data
processing system in accordance with the combustion parameter determined by the data
processing system.
The sensing apparatus may utilize an echelle grating in the multiplexer or
demultiplexer. Additional components of the multiplexer or demultiplexer may include an
optical wave guide and a collimating focusing optic. The reflective echelle grating coupled
to the collimating/focusing optic will typically have a groove spacing and blaze angle
providing for the simultaneous demultiplexing of a plurality of ranges of widely spaced
wavelengths of light. An appropriate echelle grating will typically be capable of multiplexing
or demultiplexing wavelengths equal to or greater than 670 nm through wavelengths equal to
or less than 5200 nm. To accomplish this, the echelle grating will operate at orders of
detraction from the second order to at least the fourteenth order. Such an echelle grating will
typically have a groove spacing of approximately 171.4 lines per mm and a blaze angle of
approximately 52.75 degrees.
Optionally, the sensing apparatus may have the multiplexer optically coupled to fewer
than all of the diode lasers and further consist of an optical coupler coupled to the output of
the multiplexer and the separate output of any unmultiplexed diode laser. In such an optional
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embodiment, the optical coupler will optically communicate with the pitch optic through a
select length of transmitting optical fiber. The length of the transmitting optical fiber may be
selected to minimize mode noise. For example, the transmitting optical fiber may be
implemented at a length of equal to or less than 3 meters, and be fabricated of Coming SMF
28 optical fiber which will assure that wavelengths less than 1240 nm, in particular 760 nm,
do not become multi-modal during transmission through the transmitting optical fiber.
The sensing apparatus may also consist of means to mechanically manipulate a
section of the catch side optical fiber to minimize catch side mode noise. One example of an
appropriate means to mechanically manipulate a section of the catch side optical fiber
consists of a motor having a shaft parallel to the longitudinal axis of the catch side optical
fiber which is attached to the fiber and provides a twisting motion around the longitudinal
axis. The twisting motion may consist of a sweep through plus 360 degrees and minus 360
degrees at a rate of at least 10 Hz to effectively average the transmitted signal and thereby
reduce catch side mode noise.
Optionally, the sensing apparatus may further consist of a catch side alignment
mechanism associated with the catch optic providing for the alignment of the catch optic with
respect to the direction of the projection of the mutliplexed laser output. The alignment
mechanism may increase the quantity of laser light received by the catch optic from the pitch
optic and thereby coupled to the catch side optical fiber. The alignment mechanism may
consist of an apparatus which allows the catch optic to tilt along a first axis and a second axis
orthogonal to the first axis with both the first and second axes being substantially orthogonal
to the direction of the projection of the multiplexed laser output. A stepper motor may be
used to tilt the catch optic and a data processing system may be further associated with the
catch side alignment mechanism and receive data from the detector related to the strength of
the multiplexed laser output coupled to the detector and cause the catch side alignment
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mechanism to align the catch optic. Alternatively, a separate alignment beam may be
projected to the catch optic and used as a reference for alignment purposes. A similar
alignment mechanism may be implemented on the pitch side of the sensing apparatus to
provide for alignment of the pitch optic and adjustment of the direction of the projection of
the multiplexed laser output.
Another aspect of the present invention is a method of sensing a combustion process
consisting of providing laser light at multiple select lasing frequencies, multiplexing the laser
light, and transmitting the multiplexed laser light in a pitch side optical fiber to a process
location. The process location may be a combustion chamber such as the boiler of a gas or
coal fired power plant. After transmitting the multiplexed laser light to the process location,
the method further consists of projecting the multiplexed laser light through a combustion
process, receiving the multiplexed laser light in a catch side optical fiber, demultiplexing the
multiplexed laser light and transmitting a frequency of the demultiplexed laser light to a
detector. Optionally, the method may further consist of determining a combustion parameter
from an output of the detector and controlling the combustion process in accordance with the
determined combustion parameter.
Another aspect of the invention is an echelle grating based diode laser spectroscopy
gas sensing apparatus consisting of more than one diode laser having select lasing
frequencies optically coupled to an input echelle grating having select line spacing and a
select blaze angle providing for the multiplexing of laser light at the select lasing frequencies.
The apparatus further consists of an optical fiber optically coupled to the output of the echelle
grating and receiving multiplexed laser light from the echelle grating. In addition, a pitch
optic is optically coupled to the distal end of the optical fiber with the pitch optic being
operatively associated with a process chamber which can be a combustion chamber and with
the pitch optic being further oriented to project laser light through the process chamber. The
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apparatus further consists of an output echelle grating in optical communication with the
pitch optic with the output echelle grating having a select groove spacing and a select blaze
angle to provide for the demultiplexing of laser light at the select lasing frequencies. In
addition, more than one detector sensitive at one of the select lasing frequencies is optically
coupled to the output echelle grating. The apparatus of this aspect of the invention may
further consist of a catch optic in optical communication with the pitch optic and in optical
communication with the output echelle grating. Furthermore, one or more collimating optics
may be optically coupled between the output of the echelle grating and a corresponding
detector. The echelle grating of the diode laser spectroscopy gas sensing apparatus may have
a groove spacing and blaze angle allowing the simultaneous (demultiplexing of a plurality of
ranges of widely spaced wavelengths. An appropriate echelle grating can (de)multiplex
optical channels having wavelengths equal to or greater than 670 nm through wavelengths
equal to or less than 5200 nm. Such an echelle grating would operate from the second to the
fourteenth order of refraction, and may have groove spacing of approximately 171.4 lines per
mm and a blaze angle of approximately 52.75 degrees.
Another aspect of the present invention is a method of sensing a combustion process
consisting of providing laser light at multiple select lasing frequencies, multiplexing the laser
light with an echelle grating, projecting the multiplexed laser light through a combustion
process, demultiplexing the multiplexed laser light with an echelle grating and transmitting a
frequency of demultiplexed laser light to a detector. This method may further consist of
determining a combustion parameter from an output of the detector and controlling the
combustion process in accordance with the determined combustion parameter.
Another aspect of the present invention is a pitch side optical system for use in diode
laser spectroscopy consisting of more than one diode laser having select lasing frequencies
with each diode laser being coupled to an end of a distinct input optical fiber. The pitch side
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optical system further consists of a multiplexer optically coupled to the other end of less than
all of the input optical fibers with the multiplexer outputting multiplexed laser light to a pitch
side optical fiber. Typically, the diode lasers and multiplexer will be housed in a climate
controlled room situated remotely from the combustion process chamber. The pitch side
optical system further consists of a coupler optically coupled to the far end of the pitch side
optical fiber and the far end of an unmultiplexed input optical fiber with the coupler
combining the multiplexed laser light and the unmultiplexed laser light and outputting the
combined light to a transmission optical fiber. Typically, the coupler is located near the
combustion process. The pitch side optical system further consists of a pitch optic coupled to
the transmission optical fiber. Typically, all optical fibers used in the pitch side optical
system are single mode optical fibers. The length of the transmitting optical fiber may be
selected to minimize optical noise. In particular, if laser light of relatively shorter
wavelengths, for example 760 nm, had been multiplexed with laser light of relatively longer
wavelengths, for example 1240 nm - 5200 nm, and such a multiplexed beam had been
transmitted in a suitable commercially available telecommunications optical fiber which did
not exhibit a high rate of bending and other transmission losses over the entire transmitted
spectrum, the relatively shorter wavelengths may have become multimodal over an extended
distance. Thus, the transmission fiber length may be selected to minimize the creation of
mode noise. For example, a transmission fiber length of 3 meters or less, with the
transmission fiber being Coming SMF 28 optical fiber, can transmit laser light with a
wavelength of 760 nm from the coupler to the pitch optic without the introduction of
significant multi-modal behavior.
Another aspect of the present invention is a catch side optical system for use in diode
laser spectroscopy consisting of a catch side optic optically coupled to a catch side multimode
optical fiber and means to mechanically manipulate a section of the catch side multimode
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optical fiber to minimize catch side mode noise. The mechanical manipulation may consist
of twisting the catch side multimode optical fiber around its longitudinal axis. The means to
mechanically manipulate the section of the catch side multimode optical fiber in the above
fashion may consist of a motor associated with the catch side multimode optical fiber such
that a section of fiber is held fast relative to a shaft position of the motor and the motor shaft
is repetitively swept through +360 degrees and -360 degrees of motion. The frequency of the
motor shaft sweep may be at least 10 Hz to enable effective averaging of the transmitted
signal and thereby reduce the effect of catch side mode noise.
Another aspect of the present invention is a diode laser spectroscopy gas sensing
apparatus having a diode laser with a select lasing frequency, a pitch optic coupled to the
diode laser with the pitch optic being operatively associated with a process chamber and
oriented to project laser light along a projection beam through the process chamber. This
aspect of the invention additionally includes a catch optic in optical communication with the
pitch optic to receive the laser light projected through the process chamber and an optical
fiber optically coupled to the catch optic. Li addition, the catch optic is operatively
associated with a catch side alignment mechanism which provides for Hie alignment of the
catch optic with respect to the projection beam to increase a quantity of laser light received
by the catch optic from the pitch optic and coupled to the optical fiber and a detector sensitive
to the select lasing frequency optically coupled to the optical fiber. The catch side alignment
mechanism may consist of means to tilt the catch optic along a first axis and a second axis
orthogonal to the first axis with both the first and second axes being approximately
orthogonal to the projection beam. The means to tilt the catch optic may be a stepper motor.
The diode laser spectroscopy gas sensing apparatus may also consist of an alignment beam of
light projected by the pitch optic and received by the catch optic and a data processing system
operatively associated with the detector and catch side alignment mechanism receiving data
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from the detector related to the strength of the alignment beam and further causing the catch
side alignment mechanism to align the catch side optic with the projection beam to maximize
the strength of the alignment beam coupled to the detector. The diode laser spectroscopy gas
sensing apparatus of this aspect of the invention may further consist of a pitch side alignment
mechanism providing for alignment of the pitch optic and adjustment of the direction of the
projection beam. The pitch optic may be implemented substantially as described above for
the catch optic.
Another aspect of the present invention is a method of aligning a diode laser
spectroscopy gas sensing optical system. The method consists of providing an alignment
beam of light, projecting the alignment beam through a process chamber, receiving the
alignment beam with a catch optic, the catch optic being operatively associated with the
process chamber. The method further consists of optically coupling the alignment beam from
the catch optic to a detector through an optical fiber and determining the strength of the
alignment beam coupled from the catch optic to the optical fiber. In addition, the method
consists of aligning the catch optic to maximize the strength of the alignment beam coupled
from the catch optic to the optical fiber. The method of aligning a diode laser spectroscopy
gas sensing optical system may further consist of tilting the catch optic along a first axis and
a second axis orthogonal to the first axis. Alternatively, the alignment beam may be
projected by a pitch optic and the pitch optic may be aligned as well to further maximize the
strength of the alignment beam coupled from the catch optic to the optical fiber.
Another aspect of the present invention is a method of sensing NO in a combustion
process with tunable diode laser absorption spectroscopy. The NO sensing method consists
of providing laser light at a wavelength of approximately 670 nm, transmitting the laser light
in a pitch side optical fiber to a combustion location, projecting the laser light through a
combustion process and receiving the laser light in a catch side optical fiber. The method
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farther consists of transmitting the laser light in the catch side optical fiber to a detector and
generating a signal from the detector related to the laser light transmitted to the detector. In
addition, the method consists of calculating a NO2 concentration from the signal and
determining a NO concentration from the calculated NO2 concentration. The NO sensing
method may be implemented with the provision of laser light at a wavelength of 670 run by
producing laser light with a wavelength of approximately 1340 nm with a diode laser and
frequency-doubling the laser light in a quasi-phase matched periodically polled waveguide.
A suitable waveguide is a quasi-phase matched periodically polled lithium Niobate
waveguide.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a schematic diagram of a sensing apparatus of the present invention.
Fig. 2 is a schematic diagram of a sensing apparatus of the present invention featuring
remotely located components optically coupled to components near the combustion chamber.
Fig. 3 is an illustration of an aspect of the present invention featuring multiple sensing
grids.
Fig. 4 is an illustration of a prior art single beam gas detection apparatus.
Fig. 5 is an illustration of a prior art multiple beam gas detection apparatus.
Fig. 6 is an illustration of the use of an echelle grating in the present invention.
Fig. 7 is an illustration of an echelle grating based diode laser spectroscopy gas
sensing apparatus of the present invention.
Fig. 8 is an illustration of a pitch side optical system suitable for minimizing mode
noise.
Fig. 9 is an illustration of a fiber coupled gas sensing apparatus.
Fig. 10 is an illustration of light lost between pitch and catch optics.
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Fig. 11 is an illustration of the angular acceptance cone of a fiber optic system.
Fig. 12 is a schematic diagram of an alignment mechanism of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
SENSING APPARATUS
As shown in Fig. 1 an embodiment of the present invention is a sensing apparatus 10
suitable for the sensing, monitoring and control of a combustion process. The sensing
apparatus 10 performs tunable diode laser absorption spectroscopy (TDLAS) using laser light
from a series of tunable diode lasers 12 lasing at select frequencies in the near-infrared or
mid-infrared spectrum. The output of each tunable diode laser 12 is coupled to an individual
optical fiber which may be a single mode optical fiber 14 and routed to a multiplexer 16. As
used herein, "coupled", "optically coupled" or "in optical communication with" is defined as
a functional relationship between counterparts where light can pass from a first component to
a second component either through or not through intermediate components or free space.
Within the multiplexer 16 the laser light of some or all of the frequencies generated is
multiplexed to form a multiplexed probe beam having multiple select frequencies. The
multiplexed probe beam is coupled to a pitch side optical fiber 18 and transmitted to a pitch
optic 20 or collimator operatively associated with a process chamber which, in Figure 1, is
shown as a combustion chamber 22.
The pitch optic 20 is oriented to project the multiplexed probe beam through the
combustion chamber 22. Across the combustion chamber 22 in optical communication with
the pitch optic 20 is a catch optic 24. The catch optic 24 is preferably substantially opposite
the pitch optic 20 and is operatively associated with the combustion chamber 22. The catch
optic 24 is positioned and oriented to receive the multiplexed probe beam projected through
the combustion chamber 22. The catch optic 24 is optically coupled to a catch side optical
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fiber 26 which transmits the portion of the multiplexed probe beam which is received by the
catch optic 24 to a demultiplexer 28. Within the demultiplexer 28 the portion of the
multiplexed probe beam received by the catch optic 24 is demultiplexed and each wavelength
of demultiplexed laser light is coupled to an output optical fiber 30. Each output optical fiber
30 in turn is optically coupled to a detector 32, which typically is a photodetector sensitive to
one of the select frequencies of laser light generated and multiplexed to form the probe beam.
The detectors 32 generate an electrical signal based upon the nature and quantity of light
transmitted to the detector 32 at the detector frequency. The electrical signal from each
detector 32 is typically digitized and analyzed in data processing system 34. As discussed in
detail below, the digitized and analyzed data can be used to sense physical parameters within
the process chamber including but not limited to the concentrations of various gas species and
the combustion temperature within the combustion chamber 22. The data processing system
34 can further be used to send signals through a feedback loop 36 to combustion control
apparatus 38 and thereby actively control select process parameters. In the case of a
combustion process, the process parameters controlled can include fuel (e.g., pulverized coal)
feed rates; oxygen feed rates and catalyst or chemical agent addition rates. The use of fiber
optic coupling of the electronic and optical components on both the pitch and catch sides of
the sensing apparatus 10 allows delicate and temperature sensitive apparatus such as the
tunable diode lasers 12, detectors 32 and data processing system 34 to be located in a control
room having a stable operating environment. Thus, only the relatively robust pitch and catch
optics 20, 24 need be situated near the hostile environment of the combustion chamber 22.
Figure 2 schematically depicts the overall component placement of a fiber coupled,
multiplexed sensing system 40. The sensing system 40 generally consists of a system rack
42, a breakout box 44, a transmitter head 46 having pitch optics 48, a receiver head having
catch optics 52 and connecting optical fibers. The system rack 42 is preferably located in a
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remote control room situated a distance, for example one kilometer, from the combustion
chamber 54. The control room typically will have a moderate environment. The system rack
42 contains the lasers 56, detectors 58, wavelength multiplexers 60 and wavelength
demultiplexers 62. The system rack 42 also houses the system electronics and control
software (not shown on Fig. 2). The system rack 42 may optionally house an alignment light
source 64.
The optical fibers connecting the system rack 42 with the breakout box 44 are
typically standard single-mode telecom optical fiber. This type of fiber is inexpensive, readily
available, low-loss and allows the laser light to be directed to various off-the-shelf telecom
components to manipulate the light, such as optical switches, splitters, and wavelength
division multiplexers. Without optical fiber coupling, the laser light would have to be
directed through free space all the way to the combustion chamber 54, which would be very
difficult to implement or, alternatively, sensitive electronic and optical components would
have to be situated in close proximity to the combustion chamber 54.
Also shown on Fig. 2 is a breakout box 44. The breakout box 44 is a ruggedized
enclosure located close to the boiler. The breakout box 44 contains optical switches, splitters
and couplers (collectively 66) which may be used as discussed below to direct the optical
signals to multiple transmitter-receiver head pairs.
A third group of system components as shown on Fig 2 are the transmitter and
receiver heads 46, 50. The optics and electronics in the transmitter and receiver heads 46, 50
must convert the light in the fiber 68 into a collimated beam, direct the beam accurately
through the combustion chamber 54, capture the beam on the far side of the combustion
chamber 54 and couple the beam into the fiber 70. The choice of optics to accomplish this is
determined by the transmission distance, the turbulence of the combustion zone, its effect on
the transmitted beam's quality, and the core size of the fiber 70. Preferably, the fiber core
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diameter is 50 microns, which is a compromise: a larger core will capture more of the laser
light but also much more of the background light. Fiber coupling on the catch (receiver) side
has several advantages. In particular, only light in the same location as the laser light and
traveling in the same direction is focused into the fiber 70. This drastically reduces the
amount of background light that is sensed. In an alternative embodiment, light may be
captured into one of several receiver fibers and an optical switch or other optical routing
device can select light from one fiber for routing to the detectors 58.
The use of fiber coupling at the catch side requires that the alignment tolerances of
both the transmitter and receiver optics be precisely maintained (less than 0.5 milliradian for
both the transmitter and receiver pointing). The alignment system discussed below makes it
feasible to meet these tolerances in a harsh power plant environment. Preferably, both the
pitch and catch optics 48, 52 are custom-designed and aberration-corrected for wavelengths
from 660 nm to 1650 nm so that multiple laser signals can be efficiently transmitted and
received at the same time.
SENSING APPARATUS WITH MULTIPLE SETS OF SENSING OPTICS
Referring again to Fig 1, an embodiment is depicted schematically which features
more than one set of pitch optics 20 and catch optics 24 associated with a single combustion
chamber 22. The multiplexed probe beam can be routed by a routing device which, as is
shown in Fig. 1, may be an optical switch 72 to each set of pitch optics 20. Suitable routing
devices include optical switches which may be implemented to route the probe beam with
minimal attenuation to each set of pitch/catch optics in a predetermined sequence or an
optical splitter which simultaneously routes a fractional portion of the multiplexed probe
beam to each set of optics.
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A similar optical routing device which, in Figure 1, is shown as a multimode optical
switch 74 can be employed on the catch side of the system to route the portion of the
multiplexed probe beam received by each catch optic 24 to the catch side demultiplexer 28.
Although the embodiment depicted in Figure 1 shows only two sets of pitch and catch optics,
the system can employ any number of pitch and catch optical sets. The use of fiber coupling
and a (de)multiplexed probe beam on both the pitch and catch sides of the system allows
multiple sets of pitch and catch optics to be implemented with one set of lasers 12 and
detectors 32. Without the incorporation of optical multiplexing techniques, separate sets of
lasers, detectors and fiber cables, all requiring calibration, would be needed for each
transmitter/receiver pair. As discussed in detail below, multiple transmitter/receiver pairs
allow the implementation of one or more two dimensional sensing grids over the entire
combustion chamber 22 or elsewhere, such as for sensing a downstream gas process. A
schematic illustration of two highly simplified sensing grids, a fireball sensing grid 76 and a
downstream sensing grid 78 are shown in Fig. 3. In addition, the fiber-coupled nature of the
present invention allows readily available telecommunications components to be used to
positive effect. For instance, a fiber-optics switch can be used to route the multiplexed probe
beam to different locations for measurement. 1 X N optical switches with N up to 8 are
readily available as off-the-shelf components from a variety of suppliers. Switches with N up
to 16 can be custom ordered.
A switch and multiple pairs of pitch and catch optics can be used for serial probing of
a gas species at different locations throughout the combustion chamber. For situations in
which averaged results are sufficient, serial probing of different beam paths is acceptable.
However, certain applications require instantaneous probing of an entire sensing grid. For
example, certain combustion process flows exhibits high-frequency fluctuations, or the flow
may only exist for a short period of time, e.g. shock tubes or tunnels. In such a case a 1 X N
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splitter may be used to divide the probe beam into N branches each of which occupies a
different position on the grid. Since the entire grid is illuminated simultaneously, a two
dimensional analysis can be generated very quickly. However, simultaneous two
dimensional analysis may require that each component on the catch side be reproduced for
each beam path including demultiplexers, detectors, electronics such as A/D cards and, to
some extent, computers.
Thus, embodiments featuring switches or splitters facilitate somewhat coarse
tomographic reconstruction of two-dimensional cross sections of the probed region. Using
diode lasers to do tomography of gas concentrations is a known technique, however
significant additional benefit is achieved under the present invention as a result of the use of
a probe beam which is wavelength multiplexed. The wavelength multiplexed beam allows
for the simultaneous spectroscopic analysis of more than one absorption line. Thus TDLAS
techniques which rely on more than one line, such as temperature determination, as discussed
in detail below, can be performed across the entire sensing grid. Both temperature and gas
species concentrations can be mapped in this way.
SPECIFIC APPLICATION OF TOMOGRAPHY IN SCR AND SNCR
A specific application of coarse tomography as described above is schematically
illustrated in Fig. 3 and concerns the optimization of ammonia injection in SCRs (selective
catalytic reduction) and SNCRs (selective non-catalytic reduction) for the reduction of NOX
from coal or gas fired power generation boiler effluent, m this application, a matrix of
ammonia or urea injectors 80 are placed in the flow of boiler effluent. In order to minimize
the NOX concentration, an excess of ammonia (or urea) may be added to the effluent. NOX is
a heavily regulated and highly undesirable family of air pollutants. The added ammonia
chemically reduces the NOX and forms harmless nitrogen gas and water as products.
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However, the amount of excess ammonia (or urea) added must be minimized because these
chemicals themselves are toxic air pollutants and quite expensive. Typically an excess
concentration of power plant combustion effluent is not uniform, nor is it temporally stable. In addition, one
or more of the ammonia injectors may foul at any given time causing a local decrease in the
ammonia concentration leading to a local bleed through in the NOX concentration. With the
ability to monitor the spatial concentration of ammonia or NOX with a downstream TDLAS
grid 78 sensing as described above, the present invention allows non-uniform ammonia
distributions to be detected and mitigated. Thus, optimization of the ammonia injection grid
76 with two-dimensional species concentrations and individual control over injectors allows
the optimization of the SCR/SNCR process. The detectors and ammonia injectors may be
linked to a data processing system providing automated feedback control of the ammonia
injectors.
An optimized ammonia slip detection system, such as the one described herein,
should preferably include the ability to monitor NOX concentration. NOX includes both NO
and NO2. Unfortunately, robust NIR diode lasers can only access the second NO overtone
transition occurring in the 1.7-1.8-micron region. This transition is too weak to detect NO
given the relatively low concentrations present in most effluent flows. Therefore it is not
practical to directly monitor NO concentration. However, NO2 is formed by the same
processes that form NO. These processes, known in the power generation industries as the
thermal NOX process produce both NO and NO2 with NO accounting for approximately 95%
of the total NOX concentration and NO2 accounting for the remaining 5 % under typical
conditions. The exact ratio typically depends upon temperature and the oxidizing potential of
the environment. As discussed above, this technique allows for determination of the
temperature of the sampled gas as well. However, it is expected that the NO and NO2
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concentrations will track each other. Thus NO2 can be used as a surrogate analysis species
for NO. The present invention provides the ability to monitor NO2 at a wavelength of 670
run. This wavelength is produced using a 1340 nni distributed-feedback (DFB) laser
frequency-doubled in a phase-matched periodically poled lithium Niobate waveguide. Even
though the NO2 concentration is only 5% the NO concentration, the NO2 absorption strength
is orders of magnitude stronger. Thus, NO2 can be detected readily at the concentrations
present in boilers to facilitate optimization of NOX reduction processes.
TUNABLE DIODE LASER ABSORPTION SPECTROSCOPY
The present invention performs TDLAS using techniques known to those skilled in
the art of laser spectroscopy. Generally, TDLAS is performed by the transmission of laser
light through a target environment, followed by the detection of the absorption of the laser
light at specific wavelengths, due to target gases such as carbon monoxide or oxygen.
Spectral analysis of the detected light allows identification of the type and quantity of gas
along the laser path. The details of direct absorption spectroscopy are discussed in Teichert,
Fernholz, and Ebert, "Simultaneous in situ Measurement of CO, H2O, and Gas Temperature
in a Full-Sized, Coal-Fired Power Plant by Near-Infrared Diode Lasers," {Applied Optics,
42(12):2043, 20 April 2003), which reference is incorporated herein in its entirety. The non-
contact nature of laser absorption spectroscopy makes it well-suited for harsh environments
such as the combustion zone of a coal-fired power plant, or flammable or toxic environments
where other probes cannot be used. The use of laser light provides the high brightness
necessary to get detectible transmission in the presence of severe attenuation (typically
greater than 99.9% loss of light) that may be seen in some of these environments. To better
withstand the harsh conditions of the target applications, the laser light may be brought in to
the target environment through armored optical fiber.
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Effective sensing of temperature or multiple combustion process component gasses
requires the performance of TDLAS with multiple widely spaced frequencies of laser light.
The frequencies selected must match the absorption lines of the transitions being monitored.
For example, as discussed above it is useful to monitor NO2 at a wavelength of 670 run to
approximate emission NO concentrations. It is also quite useful to monitor oxygen, water
(temperature), and carbon monoxide in a coal-fired utility boiler. Suitable absorption lines,
and thus suitable lasing frequencies can be selected based upon an assumption that the laser
probe path length through a combustion chamber is equal to 10 meters and that the mole
fraction of each species is CO (1%), O2 (4%), CO2 (10%), and H2O (10%). For frequency
selection purposes, the process temperature can be assumed to be 1800 K which is slightly
higher than what is typically observed in a coal fired plant, but the cushion serves as a safety
factor in the calculations.
For example, three water absorption lines can be selected for TDLAS that meet the
following criteria:
1. Lower state energy of ~ 1000, 2000, and 3000 cm"1 respectively
2. Provides a convenient absorbance of around 0.1 - 0.4 that, in turn, leads to
approximately 20% beam absorption on resonance.
3. The optimum situation is to utilize transitions in the 1250 to 1650 nm region where
inexpensive, high power, DFB diode telecommunications lasers are available.
4. The transitions must be well separated to allow for easy multiplexing.
5. The selected wavelength must be efficiently diffracted by the existing (de)multiplexer
gratings.
Suitable water lines occur at the following wavelengths:
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TABLE 1

Wavelength
(nm) Wavenumber
(cm"1) Lower State
Energy (cm"1) Grating
Order Absoprtion
at 1800 K
and 10 M UNP Grating
Efficiency
(model)
1349.0849 7412.432 1806.67 6.87 19.7% 81%
1376.4507 7265.062 3381.662 6.73 28.1% 77%
1394.5305 7170.872 1045.058 6.65 6.8 % 72%
No interference from any other combustion gases is anticipated. The most likely
species to interfere, CO2 was modeled and there are no strong, interfering lines in the 1.3-
1.4 micron region.
Similarly, a suitable carbon monoxide line can be selected based on the work of Ebert
referenced and incorporated above. A suitable carbon monoxide line is found at 1559.562
nm using the R(24) line in a coal-fired utility boiler. Selection of this line avoids interference
from water and carbon dioxide. Known gratings are quite efficient in this wavelength region
since it is in the optical communications C band. The absorbance at this wavelength is
expected to be 0.7%.
In addition, oxygen can be measured at 760.0932 nm. The preferred (de)multiplexing
grating efficiency calculates to be only 40% in this region, however suitable laser power
should be available for reasonable measurement efficiency.
As discussed herein, the use of fiber coupling on both the pitch and catch sides of a
TDLAS sensing apparatus requires critical alignment of the pitch and catch optics. Active
alignment is preferably accomplished with a select alignment wavelength. One possible
alignment wavelength is 660 nm because high power (45 mW) diodes are available at this
frequency and 660 nm would be near the peak of 14th order grating operation. Other
alignment wavelengths may be determined to be equally or more suitable.
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In summary, a reasonable set of wavelengths selected for multiplexing to a probe
beam for TDLAS as embodied in the present invention are as shown in Table 2. It should be
noted that this wavelength set is for one embodiment of a TDLAS sensing apparatus suitable
for the sensing and control of a coal fired power plant. Other wavelength sets can be equally
suitable.
TABLE 2

Purpose Wavelength (nm)
Alignment 660
O2 b-a band 760.0932
H2O (moderate temp, line) 1349.0849
H2O (high temp, line) 1376.4507
H2O (low temp, line) 1394.5305
CO R(24) of (2,0) overtone 1559.562
SPECIFIC BENEFITS OF TDLAS USING MULTIPLEXED BEAM
A particular advantage of TDLAS with a wavelength-multiplexed probe beam is
increased accuracy of temperature measurements. In order to make accurate concentration
measurements with TDLAS, the temperature of the monitored gas must be known. The
strength of a molecular absorption is a function of temperature. Thus, to convert the
amplitude of an absorption feature to concentration, the temperature must be known. Certain
previous attempts to measure the concentration of combustion species such as CO suffer from
insufficiently accurate temperature measurements leading to errors in quantification. This is
particularly true for diode laser based ammonia slip monitors that have traditionally not
incorporated temperature measurement at all. hi the sensing system of the present invention,
temperature may be determined by measuring the ratio of the intensity of two or more
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molecular water lines. The ratio of the integrated intensity of two lines is a function of
temperature only (assuming constant total system pressure). Thus, in principle, two lines
provide an accurate temperature. However, in the case of a non-uniform temperature
distribution (as is typically found within an industrial combustion process), two lines do not
suffice to determine the temperature distribution. In such a non-uniform temperature
distribution, two lines can only determine a "path-averaged" temperature. In contrast,
measuring the integrated amplitude of more than two lines (of the same species) allows
temperature non-uniformity to be probed. An example of this technique has been
demonstrated using oxygen as the probe molecule by Sanders, Wang, Jeffries and Hanson in
"Applied Optics" (vol. 40, num. 24, 20 August 2001), which reference is incorporated herein
in its entirety. The preferred technique relies on the fact that the distribution of peak
intensities measured along a line of sight is not the same for a path at an average temperature
of 500 K, for example, as it is where one half of the path is at 300 K and the other half is at
700 K.
In addition to the benefit of more accurate temperature measurement, the use of a
multiplexed probe beam can allow for the simultaneous monitoring of more than one
combustion gas species, allowing for more refined control over the combustion process.
ECHELLE GRATING BASED APPARATUS
The present invention benefits from the use of relatively inexpensive and commonly
available optical components designed for use in the telecommunications industry. The
telecommunications apparatus serve well to fiber couple the pitch and catch sides of the
system. Telecommunications applications typically use optical multiplexers which, accept
multiple light beams at wavelengths which are relatively close spaced and separated by a
constant value (such as 0.8 nm). The light beams are then generally coupled onto a single-
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mode optical fiber. Demultiplexers perform the inverse process. Telecommunications
equipment is typically designed to perform at wavelengths between 1520 and 1620 run, with
the Optical C-band, 1528 - 1563 nm, being the most utilized.
In the case of (de)multiplexerss the same physical device may be used for either
multiplexing or demultiplexing, depending upon the direction of the light which passes
through it. Consequently, the term "multiplexer" or "mux" as used herein will be understood
to include both multiplexing and demultiplexing functions.
Optical multiplexers may use any of several technologies to accomplish the
mux/demux function. However, echelle grating-based muxes are advantageous in that they
may be incorporated into a very simple and compact design. Echelle gratings are relatively
course diffraction gratings that operate in orders other than the first order with blaze angles
typically greater than 45 degrees. The course line spacing on the grating combined with high
order operation results in a large angular dispersion that allows the device to be compact.
Some telecommunications applications may require that other wavelengths well
outside of the C band be simultaneously serviced by optical multiplexers (for instance 1310
nm). Additionally, applications outside the telecommunications field such as the TDLAS
sensing and control apparatus of the present invention may require the multiplexing of laser
light at widely separated wavelengths, such as separations of approximately 100s of nm. An
example illustrative of the benefits of an echelle grating based multiplexed sensing apparatus
is developed in Figs. 4-7. Fig. 4 illustrates a gas sensing apparatus 82 in which light 84 is
directed through a flame 86 from one side. A sensor 88 on the other side of the flame detects
the transmitted light and determines how much light is absorbed by the gasses in the flame
86. In the device illustrated in Fig. 4, only a single beam of light is passed through the flame
86. The wavelength of the light may be chosen to correspond to the absorption wavelength
of a particular gas. Alternatively, the light may be a white light which, after passing through
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the flame 86, is spit into various wavelengths, such as by a prism. The absorption at each
wavelength of interest can then be measured.
In a slightly more sophisticated prior art alternative, a device such as that illustrated in
Fig. 5 may be used to pass a number n of separate beams of light 90A - 90n through the flame
92. Each beam of light 90A - 90n is at a different wavelength of interest and sensors 94A -
94n on the other side of the flame 92 measure the absorption at each wavelength, indicating
relative amounts of selected gases of interest. There are several drawbacks to using multiple
separate beams. First, access to the flame may be limited and attempting to project the
multiple beams through the limited space may be awkward, if not impossible. Second, there
is typically turbulence in the flame as well as pockets of non-uniformity. The multiple
beams, even if very closely spaced, may not pass through the same sampling space and
therefore not generate consistent or comparable results. Finally, the projection and sensing
optics and detectors are more complex and costly in a multiple-beam apparatus compared to
those in a single-beam apparatus.
The echelle grating multiplexer based sensing device of the present invention has
significant advantages over the prior art. An echelle grating provides unusual flexibility by
being able to operate in orders other than the first order with blaze angles typically greater
than 45 degrees. For instance, the Zolo Technologies, Inc. Zmux™ is optimized to operate in
a Littrow configuration in the 6th order at 1545 nm with a mechanically ruled grating having a
line spacing of 171.4 lines/mm and a blaze angle of 52.75 degrees. The grating equation for a
Littrow mount is:
mX = 2dsinGb (1)
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where m is the order, X is the wavelength, d is the spacing between rulings, and 9b is the
blaze angle.
For a given grating, mX is a constant. For the Zmux grating referenced above, mX =
6(1.545) = 9.27 microns. Such a grating provides optimum efficiency for 1.545 microns in
6th order. However, the grating also provides very high efficiency for other orders as well.
For instance, the 7th order occurs at 9.27/7 = 1.32 microns. Thus, a grating such as the Zmux
can simultaneously multiplex C band light as well as 1310 nm light with high efficiency. Fig.
6 illustrates an echelle grating 96 multiplexing light 98A - 98n to be collimated by a
collimator 100 into a single beam 102.
Of particular relevance to the present invention are applications outside of the
telecommunications field for multiplexing laser light at widely separated wavelengths, often
over 100s of nm. In applications such as the present TDLAS based gas-sensing apparatus, it
is critical for all wavelength components of a probe beam to sample the same region of space
and many wavelengths may be necessary to detect a single species or to detect multiple
species. For these applications, echelle grating-based mux/demuxes provide a unique
solution. For example, the echelle based de/multiplexer described above is capable of
muxing a substantial wavelength region about the central wavelengths given in Table 3 below
where each wavelength region corresponds to a different grating order.
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TABLE 3

Order Central Wavelength
(microns) Approximate
Wavelength
Range (microns)
2 4.63 4.40-4.80
3 3.09 2.90-3.30
4 2.32 2.15-2.40
5 1.85 1.70-1.95
6 1.55 1.50-1.57
7 1.32 1.24-1.39
Higher orders up to and beyond the fourteenth order may also be multiplexed with
correspondingly narrower wavelength ranges. It is noteworthy that single mode transmission
for all of these wavelengths is not possible in readily available optical fiber. One aspect of a
gas-sensing apparatus 104 of the present invention is schematically illustrated in Fig. 7. This
aspect highlights the advantages of TDLAS with a multiplexed laser output has over the prior
art embodiments discussed above. In the Fig. 7 embodiment, a number n of laser sources
106A - 106n operating at widely separated wavelengths are multiplexed by an echelle grating
108 onto a single optical fiber 110. The light from the single fiber 110 is collimated by a
collimator or pitch optic 112 and passed through the sample 114 (such as a flame) to be
analyzed. After passing through the sample 114, the light is demultiplexed by another echelle
grating 116. The transmitted light at each wavelength is detected by a corresponding
photodetector 118A - 118n. The lasers 106A - 106n are tuned over a narrow spectral region
(such as 1-2 urn) and absorption by the sample 114 is monitored over each spectral region
scanned. In this way, the gas under test can be fully identified and quantified. Other
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parameters such as gas temperature and pressure may be measured as well. In addition to
combustion sensing, widely separated wavelength echelle grating mux/dermix technology
may enable medical devices to measure gases in exhaled breath and homeland defense
devices to detect chemical warfare agents. Other applications are possible in the fields of
display and microscopic vision technology by using the echelle based muxes and
red/green/blue coupler devices.
MODE NOISE
The optical train of the TDLAS system of the present invention, and similar
implementations which require a signal multiplexed from widely spaced wavelengths
presents many design challenges due to the opposing design requirements of the reduction of
mode noise and high efficiency light collection. Mode noise is defined herein as a change in
the signal level of detected light that results from non-uniform time and wavelength varying
light distribution in the core of a fiber used to collect and transport the light to and from the
process chamber being measured.
In a multimode fiber, different modes propagate at different velocities due to
refractive index variations. The intensity distribution in the fiber is then a speckle pattern
resulting from interference of all the propagating modes that have undergone different
effective path lengths. If all light in the speckle pattern is collected and detected, then
constructive and destructive interference cancel exactly and the total transmitted power does
not depend on wavelength or fiber length. If clipping, vignetting or other loss is introduced,
the exact cancellation fails and the detected power changes with wavelength and/or time. A
general expression for the detected power after a length, z, of fiber is:
P = Po + Sjj Cjj EiEjCos[(27w0Anijz)/c + A 30

WO 2004/090496 PCT/US2004/010048
where Po = wavelength independent average power
E; = amplitude of light in the ith transverse mode
cy = overlap integral between the ith and jth transverse mode
Ally = refractive index difference between ith and jth modes
A(j)y = phase shift between ith and jth modes due to temperature and stress
For an orthonormal set of modes and no loss, cy = 0. However, with any beam
clipping or vignetting or any other mode dependent loss will cause some cy ?O. This will
lead to ripples in the average transmitted power.
For a typical graded-index fiber with a 50 micron core, the total index change, An, is
~1%, but most modes spend the bulk of transmission time close to the fiber core center, and
therefore, Any approximately 135 modes, which is sufficiently coarse to produce prominent mode noise
during a wavelength scan given reasonably achievable beam clipping levels.
As a concrete modal noise example, one may consider the simplest possible system
that exhibits mode noise: a rectangular waveguide supporting only the lowest mode in one
dimension and only the two lowest modes in the orthogonal dimension:
Lowest mode: Ei = Ei° [exp i(kz - ©t)]cos 7tx/2a
Next mode: E2 = E20 [exp i(kz - cot)]sin 7ix/a
The intensity at a point z along the fiber is:
I(x) = |Ei + E2|2 and the total power is P= jEi + E2|2dx (3)
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where the integral must include the effects of clipping and vignetting.
In the absence of clipping, P~ Ei2 + E22 and there is no wavelength dependence.
Adding clipping amounts to changing the limits of the integral. It can be shown that clipping
results in an additional term ~ EiEicosA(|> where A If single-mode fiber could be used in the catch side optical train of the present
invention, mode noise would not be an issue. However, multimode fiber must typically be
used in the catch side optical train of the present invention for two reasons. First, after
traversing the measurement volume (a combustion chamber with a measurement path in
excess of 10 meters), the initially single-mode (Gaussian spatial distribution) beam is
significantly degraded in quality. Thus, the coupling efficiency of this severely distorted
beam into single-mode fiber would be veiy poor. This is an unacceptable situation since the
beam is attenuated by 3 - 4 orders of magnitude when passing through the measurement
volume primarily due to scattering and obscuration by soot and fly ash. The additional
attenuation resulting from using single-mode fiber would preclude measurement. Second,
refractive beam steering effects in the fireball cause the position and pointing of the beam to
be unstable. Given these effects, it would be difficult to "hit" the core of a single-mode fiber
with any regularity.
On the other hand, the core of a multimode fiber presents at least 25 times the target
cross-sectional area of a single-mode fiber. Thus, the effects of beam steering can be
significantly reduced. In addition, since the coupling efficiency into multimode fiber is
independent of the spatial mode of the light, the poor beam quality obtained after passing
through the fireball is not an issue.
However, mode dependent losses occurring in the multi-mode fiber train are a
significant design challenge. The light distribution emanating from the core of a multimode
fiber exhibits a random speckle pattern, i.e. a random pattern of light and dark areas caused
32

WO 2004/090496 PCT/US2004/010048
by constructive and destructive interference between different modes of the fiber. If the
speckle pattern was totally invariant as a function of time and wavelength, it would not
present a problem. However, slow variations in the speckle pattern particularly as a function
of wavelength can cause mode noise if the beam is clipped anywhere in the multirnode catch
side optical train as described above. This clipping is impossible to avoid; it can only be
reduced. Therefore, additional measures to reduce mode noise must be implemented to
improve the detection sensitivity of the system.
There are several ways in which to mitigate mode noise. From equation 2 above,
mode noise may be reduced by:
1) reduce mode dependent losses, i.e. reduce clipping thereby keeping the cy small
2) reduce z, thereby increasing the period of the model noise to be much greater than the
absorption lines of interest
3) reduce Any by using low dispersion fiber
4) scramble the modes; but not all mode scrambling techniques are equally effective, as
is described below.
Preferably, the catch optics of the present invention are designed and implemented to
incorporate all of the above in order to reduce modal noise. The optics are designed such that
any beam clipping should occur at a low level given near perfect alignment of the system.
Efforts should be made to keep the length of multimode fiber to a minimum; however, for
some applications z must be long in order to have the control electronics in an
environmentally controlled area. The value of Any may be reduced by using premium low-
dispersion multimode fiber. In addition, excellent results may be obtained by scrambling the
modes by mechanical manipulation of a catch side multimode fiber.
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WO 2004/090496 PCT/US2004/010(148
The speckle pattern exhibited in a multimode fiber varies as a Sanction of lime and
wavelength and also as a function of the mechanical position of the fiber. Flexing the fiber
and manipulating it in specific ways can cause the speckle pattern to change. If these
mechanical manipulations are performed continuously, over a period of time, the spatial
distribution of light emanating from the fiber averages to a relatively uniform pattern. The
crux of the scrambler of the present invention is to reduce mode noise by mechanically
manipulating multi-mode fiber to produce, on average, a uniform light beam that does not
produce mode noise when subjected to inevitable low-level beam clipping.
Some specific modes of fiber manipulation are more effective at reducing mode noise
than others. In particular, twisting the fiber about its longitudinal (z) axis relative to some
other point on the fiber causes the speckle pattern to change. In particular, the dominant
change obtained is a rotation of the speckle pattern around the z-axis. Of interest is the fact
that the pattern does not rotate as far around the axis as the fiber is mechanically rotated. A
secondary effect is that the actual light distribution is somewhat altered by the rotation. The
rotation of the speckle pattern is not due to stress-induced refractive index changes in the
fiber, although this may explain small changes in the speckle intensity pattern. Rather, the
rotation is due to the light's inability to completely follow the waveguide as it is manipulated
in a torsional motion.
This observation can be used to virtually eliminate mode noise caused by the use of
multimode fiber for the catch side optical train. A highly preferred embodiment of the
present invention uses a hollow shaft motor through which the multi-mode fiber is placed and
fastened. A remote section of fiber is held fast relative to the shaft position of the motor, and
the motor is repetitively swept through +360 degrees and then -360 degrees of motion. The
frequency of this motion preferably is greater than or equal to 10 Hertz to enable effective
34

WO 2004/090496 PCT/US2004/010048
averaging of the transmitted signal, and significantly reduce the effect of catch sids mode
noise.
The pitch side optical train of the present invention also presents a significant design
challenge due to the necessity of producing a single-mode beam for all wavelengths to be
transmitted through the measurement region. If single-mode fiber could be used throughout
the pitch side optical train, mode noise would not be an issue. However, fiber only operates
as a single-mode waveguide over a limited wavelength window. Beyond the short
wavelength cutoff for a particular fiber, light can be transported through the fiber in several
higher order spatial modes. These higher order modes will interfere to produce a speckle
pattern when the light exits the fiber. The speckle pattern is time and wavelength-varying.
Even a small amount of beam clipping then gives rise to noise in the measurement.
On the contrary, if a fiber is selected that has a single-mode cutoff that matches the
shortest wavelength that needs to be transmitted, the longer wavelengths will suffer a
substantial loss when coupled into the fiber and the fiber will exhibit extensive bending losses
for the longer wavelengths.
This problem can be acute in the fiber coupled, wavelength multiplexed TDLAS
sensing and control device of the present invention due to the need to multiplex wavelengths
as long as 1.67 microns with wavelengths as short as 760 nm or 670 nm. There is no known
single commercially available fiber that will provide single mode operation, high coupling
efficiency and low bending losses for such a broad range of wavelengths. Photonic crystal
fiber may in the future provide a solution to this dilemma, but Photonic crystal fiber
technology is currently in its infancy.
As shown in Fig. 8, the current invention alleviates the problem of multiplexing and
pitching light in a single mode beam from 670 nm or 760 nm to 1.67 microns by utilizing a
very short transmission section of multimode fiber 120 that does not allow the higher order
35

WO 2004/090496 PCT/US2004/010048
spatial modes for a wavelength shorter than the single mode cutoff to develop. Referring to
equation 2 above, if the length, L, of multi-mode fiber is short, then mode noise will be
minimized. In this case, for example, if 760 run light is coupled to a short section of single
mode fiber with a cutoff wavelength of 1280 nm (e.g. Corning SMF 28), the 760 nm light
remains single-mode for at least a few meters. Therefore a solution to pitch side mode noise
is to couple the 760 nm light into a fiber which is single mode for wavelengths longer than
1280 nm but could be multimode for 760 nm, with only a short distance to go before it is
collimated to be transmitted through the measurement zone.
A schematic diagram of such a system is shown in Fig. 8 and Fig. 2. Refemng first to
Fig. 8, multiple diode laser sources 120 lasing at widely spaced lasing frequencies are
coupled to discrete single mode optical fibers 122 A - 122n. The diode lasers lasing at
wavelengths between 1349 nm and 1670 nm are multiplexed with multiplexer 124. The
output of multiplexer 124 is coupled to a pitch side fiber optic 126 having suitable
dimensions for transmitting light with wavelengths ranging from 1349 nm -1670 ;nm, both
without substantial transmission losses and without the introduction of mode noise:. A
suitable fiber optic for these wavelengths is Corning SMF28. However, the 760 nm input, if
multiplexed and coupled to an SMF28 optical fiber would, after transmission over a relatively
short distance, become multimodal. Accordingly, the output of the 760 nm laser is coupled to
a fiber which is single mode for wavelengths less than 1280 nm such as SMF750. The laser
light transmitted in the input fiber 122n and the multiplexed laser light transmitted in the
pitch side optical fiber 126 can be coupled nearby the pitch optic 128. The coupler 130 and
pitch optic 128 are preferably optically connected by a short length of transmission optical
fiber 132 with the transmission optical fiber 132 being selected to transmit all of the coupled
and multiplexed wavelengths without significant loss. A suitable transmission optical fiber
for the system depicted in Fig. 8 would be Corning SMF28. Provided that the transmission
36

WO 2004/090496 PCT/US2004/010048
optical fiber is relatively short, the 760 run laser light coupled to the transmission optical fiber
132 will not exhibit multimodal behavior. For the system and fibers depicted in Fig. 8, it has
been determined that the transmission optical fiber must be kept to a length of 3 meters or
less to avoid the introduction of significant multimodal noise.
A similar system is shown in Fig. 2 where coupler 136 receives input from both a 760
nm diode laser and a multiplexed beam from diode lasers having substantially longer
wavelengths.
ALIGNMENT SYSTEM
Preferably, the sensing system of the present invention incorporates an auto alignment
feature that allows the pitch and catch optics to maintain optimal alignment even though they
are bolted on to a boiler or other hostile process chamber which is, itself, subject to
movement from thermal effects, wind and vibration. In a highly preferred embodiment of the
present system, both the pitch and catch optics are mounted on feedback-controlled tip/tilt
stages. The requirement that both pitch and catch optics be mounted on tip/tilt stages results
from the fact that the sensor is totally fiber-coupled. Thus, multiplexed light is launched
across the measurement region by a collimating pitch optic attached directly to an input fiber,
and the catch optic couples the transmitted light directly into an output fiber that typically is a
multimode fiber. Accordingly, the catch optic must be oriented so that it is collinear with the
beam emanating from the pitch optics. This is necessary so that the focused transmitted beam
will arrive within the acceptance cone of the multimode catch fiber.
In order to discriminate transmitted laser light from intense background light (for
example, from the flames in a coal furnace), the field of view and focus of the detector can be
limited to sense only light with the same direction and position as the input laser light. This
may be done conveniently by focusing detected light into an optical fiber coupled to a
37

WO 2004/090496 PCT/US2004/010048
suitable detector. The basic optical system design of an embodiment of the present invention
is shown schematically in Fig. 9. The transmitter 136 of Fig. 7 consists of a pitch optic 138 or
collimator such as a collimating lens of one or more than one layer and associated mounting
and alignment structures and electronics. Similarly, the receiver 140 of Fig. 7 consists of a
catch optic 142 or collimator of similar or varied construction from the pitch optic and
associated mounting and alignment electronics. The efficiency and background
discrimination of a transmitter-receiver pair are tied to alignment tolerance. For highest
efficiency and discrimination, the alignment tolerances for both the transmitter and receiver
are severe. The transmitter must be pointed accurately enough so that most of the transmitted
light strikes the clear aperture of the catch optic 146, as indicated in Fig. 10. For a typical
system, this amounts to a 1 cm tolerance over a typical transmission distance of 10 meters, or
1 milliradian. (With target distances between 5 and 30 meters and launched spot sizes
between 1 and 3 cm, diffraction is a small contribution.)
As is graphically illustrated in Fig. 11, the receiver's angular acceptance is determined
by the fiber core 148 diameter divided by the catch optic 150 focal length. A shorter focal
length will increase the angular acceptance, but the receiver clear aperture becomes
correspondingly smaller. A compromise having adequate clear aperture and angular
acceptance is to use a 50 mm focal length lens and a 50 micrometer core fiber. This results in
a 2 cm clear aperture and a 1-milliradian cone of angular acceptance.
A preferred alignment system must therefore position two optics to point at each other
with tolerances of 1 milliradian in both tip and tilt, for a total of four degrees of freedom.
These four degrees of freedom might possibly be accomplished by rough alignment of one
side followed by a four-dimensional alignment (tip, tilt, and lateral position in x and y) of the
other side, but this assumes that large lateral motions are permissible. Since access; ports for
target environments may be as small as 1 inch, this is potentially a problematic solution.
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WO 2004/090496 PCT/US2004/010048
Alternatively, active pointing alignment at both ends can ensure proper alignment when
limited space is available for lateral movement.
The critical alignment of the pitch and catch optics must be maintained in a harsh and
variable environment. Vibration, wind loading, temperature change and other structural shifts
may all lead to misalignments, as will mechanical creep in the transmitter and receiver
optomechanics. Misalignment can also be expected after periodic maintenance, when the
transmitter and receiver heads are removed for cleaning and then re-mounted. Ideally, the
optical system of the present invention will be able to maintain its 1 milliradian optical
alignment in the face of system misalignments that could approach 50 milliradians. The
alignment system should also retain position during power outages and tolerate total loss of
signal, and be turned off without losing alignment. Finally, the system itself must preferably
be ragged enough to function continuously for an extended period of time in an exposed,
industrial environment.
Fig. 12 schematically illustrates an embodiment of alignable pitch or catch optics.
The transmitter and receiver are similar in design: the transmitter generates a collimated
beam of laser light from light emerging from an optical fiber, and the receiver captures a
collimated beam of laser light and focuses it into a fiber. (It is possible to send light backward
through this optical system, and most of the elements of the transmitter and receiver are
identical.) The transmitter and receiver optics may be mounted in NEMA-4 enclosures to
protect them from the environment. The following description applies to either the: transmitter
or receiver module.
As shown in Fig. 10, the pre-collimated fiber/lens pair 152 is attached to a kinematic
tilt stage 154 positioned to allow tip and tilt perpendicular to the optical axis. Two direct-
drive stepper motors 156 accomplish tip and tilt. These motors are controlled by computer via
an Ethernet or similar connection. This connection may be through optical fiber in order to
39

WO 2004/090496 PCT/US2004/010048
avoid electrical interference. The stepper motors 156 hold their position when power is
removed, so the optical alignment is unaffected by electrical power outages.
During periodic or continuous system alignment, the control computer monitors the
amount of laser light that is transmitted and detected. Preferably, a discrete alignment
wavelength may be provided for continuous or periodic alignment proceedings such as the
visible light source 64 of Fig. 3. Any misalignment will reduce this detected signal. In auto-
alignment mode, the computer measures the detected signal, directs one of the two stepper
motors to move a small amount in one direction, then re-measures the detected signal. If the
signal increases, then the computer directs the stepper motor to move again in the same
direction until the signal does not increase. The computer then directs the other stepper motor
to move along the orthogonal axis to maximize the detected signal, then repeats the whole
process for the other sensor head. As the detected signal increases, the detector amplifier
gain automatically decreases so that the auto-alignment process proceeds over several
decades of signal size. The auto-alignment system can function with detected powers from
nanowatts to milliwatts.
This "hill-climbing" algorithm is able to align the system after near-total loss of
signal, in the presence of substantial noise, and is tolerant of beam blockages, power outages,
mechanical shocks and other disturbances that could cause other alignment systems to
misalign to the limits of the control electronics. All that is required for auto-alignment is a
finite signal with a global maximum in position space. Depending on specific installation
conditions, auto-alignment may occur periodically at set intervals such as every hour or as
needed after an extended period such as days of operation. The control computer may
monitor the detected signal and auto-align only when the signal drops below a pre-set
threshold.
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WO 2004/090496 PCT/US2004/010048
The transmitter and receiver modules may incorporate several other features useful
for industrial applications. Optional sensors may detect when the modules are moved out of
position for cleaning or maintenance, and all lasers are turned off for safety. As shown on
Fig. 10, All electrical and optical connections may made through a hinge 158 so that all such
connections are undisturbed by maintenance operations. The enclosure 160 protects the
sensitive internal optics from contaminants, and is preferable hosable. The hinge range of
motion may be restricted to avoid operator injury. Preferably, each sensor head will require
less than 10 watts of input electrical power during auto-alignment, and less than 0.1 watt after
auto-alignment is complete.
Alternate designs may be suitable for different applications. Considerable size and
weight reduction are possible if NEMA-4 enclosure rating is not required. Different
transmission distances may allow optics of different focal length and clear aperture to
optimize the captured signal. As an alternative to the stepper motor-driven tilt stage described
above to control pointing by moving the entire fiber-lens assembly, the fiber may be moved
laterally relative to the lens to effect the same pointing change while moving a much smaller
mass. Different electromechanics such as piezoelectric elements or voice coils may also be
used to increase the speed of the auto-alignment system.
In addition to the alignment concerns discussed above, the specific choice of pitch and
catch optics can affect the performance of the TDLAS sensing system of the present
invention in several ways:
(1) Signal strength coupled to the detectors depends on pitch/catch efficiency.
(2) The amount of undesirable background emission coupled to the detectors depends
on catch optics etendue.
41

WO 2004/090496 PCT/US2004/010048
(3) The effects of few-mode noise at 760 nm are very sensitive to the pitclii/catch
configuration.
(4) The noise characteristics (small but more steady or larger with wild swings) are
expected to depend on the launched beam size. A larger launch beam is preferable.
(5) The system misalignment sensitivity is a direct function of pitch and catch focal
lengths and associated fiber sizes.
A very simplistic picture of a typical coal fired power plant combustion zone can be
adopted for optical component selection analysis. The purpose of such analysis is to focus on
the general effects on a laser beam passing through the fireball with as little knowledge of the
fireball details as possible. Traversing the fireball has three effects on a light beam:
(1) Soot particles absorb some of the light.
(2) Large-angle refraction or scattering prevents some of the light from reaching the
catch optic.
(3) Light passes through numerous small thermal gradients and is thus steered
randomly but still reaches the catch optic.
Only the third category of light is available for collection. Assuming that a typical ray
of light undergoes multiple refracting events while traversing the fireball, the direction of the
ray follows a random path, and can drift away from its initial direction. If the ray is part of a
larger beam composed of other rays that undergo similar but not identical drifts, then the
effect of the fireball on the beam causes four distinct types of changes:
42

WO 2004/090496 PCT/US2004/010048
(1) Change in the overall direction of the entire beam
(2) Change in the position of the centroid of the beam
(3) Change in the beam size
(4) Change in beam divergence/wavefront flatness
These four types of changes are parameters which include all the major effects on the
beam that will affect collection efficiency, without regard for the physics leading to these
effects.
If the directions of the rays of light in the fireball are undergoing random drift then the
ray directions may diffuse away from the initial (nominally optimum) direction according to
a standard diffusion dependence. However, the distance of a ray of light from the original
axis depends on its prior directions. Thus, for a given amount of rms beam steering,
determined by the details of the fireball, a directly proportional amount of beam offset can be
expected. If a laser beam traversing the fireball is blown up to several times its original size
then the same relationship will hold between the final beam size and final beam divergence.
Light collection efficiency can be estimated if we know the angle, location and beam
size of the light incident on the catch optics. The estimate assumes simple ray optics, flat-top
intensities and a simple estimate the amount of light incident on the catch optic that is within
the fiber numerical aperture NA and which is boresighted to strike the core of the fiber. The
end result is a "hill" in offset-angle space. Assuming optimum alignment, collection
efficiency is close to the top of the hill but may be rapidly moving over and around the hill as
beam angle and position fluctuate. Preferably, the collection efficiency lull will be both as tall
and as broad as possible. Several points about the hill are worth noting:
43

WO 2004/090496 PC17US2004/010048
(1) The peak height of the collection efficiency hill (for zero beam offset and tilt) is
proportional to the square of the catch optic etendue (focal length times NA) unless the catch
optic is large enough to capture the entire incident beam, at which point the catch efficiency
is 100%.
(2) The hill is elliptical, and changing the catch focal length makes one ax::s longer
and the other shorter.
(3) The fluctuation in light collection efficiency due to beam jitter is a noise source.
Based upon the foregoing analysis techniques, the signal to noise ratio of different
pitch/catch combinations may be compared. Assuming that the multiplicative noisie is the
same, different catch optics differ in final performance only if the fireball background noise
or detector noise are dominant.
The objects of the invention have been fully realized through the embodiments
disclosed herein. Those skilled in the art will appreciate that the various aspects of the
invention may be achieved through different embodiments without departing from the
essential function of the invention. The particular embodiments are illustrative and not meant
to limit the scope of the invention as set forth in the following claims.
44

1. A sensing apparatus comprising:
more than one diode laser each having a select lasing frequency;
a multiplexer optically coupled to more than one of the diode lasers, the
multiplexer outputting a multiplexed laser output, the multiplexed laser output
being optically coupled to a proximal end of a pitch side optical fiber;
a pitch optic optically coupled to a distal end of the pitch side optical
fiber, the pitch optic being operatively associated with a combustion process
and oriented to project the multiplexed laser output through the combustion
process;
a catch optic operatively associated with the combustion process in
optical communication with the pitch optic to receive the multiplexed laser
output projected through the combustion process;
a catch side optical fiber optically coupled to the catch optic at a
proximal end;
a demultiplexer optically coupled to a distal end of the catch side
optical fiber, the demultiplexer demultiplexing laser light of each of the select
lasing frequencies; and
a detector optically coupled with the demultiplexer, the detector being
sensitive to one of the select lasing frequencies.
2. The sensing apparatus of claim 1 further comprising a data processing
system receiving input from the detector and determining a combustion parameter.
3. The sensing apparatus of claims 1 through 2 further comprising means
for affecting the combustion parameter operatively associated with the data
processing system.
4. The sensing apparatus of claims 1 through 3 further comprising a
plurality of detectors optically coupled with the de-multiplexer, each detector being
sensitive to one of the select lasing frequencies.
45"
AMENDED PAGE

5. The sensing apparatus of claims 1 through 4 wherein one of the
multiplexer and demultiplexer comprises an echelle grating.
6. The sensing apparatus of claims 1 through 5 wherein the multiplexer is
optically coupled to fewer than all of the diode lasers and further comprising an
optical coupler optically coupled to the distal end of the pitch side optical fiber and a
distal end of an un-multiplexed input fiber, the optical coupler optically coupling
multiplexed laser light from the pitch side optical fiber and un-multiplexed laser light
from the un-multiplexed input optical fiber, the optical coupler being in optical
communication with the pitch optic.
7. The sensing apparatus of claims 1 through 6 further comprising means
to mechanically manipulate a section of the catch side multimode optical fiber to
minimize catch side mode noise.

8. The sensing apparatus of claim 1 through 7 further comprising a catch
side alignment mechanism operatively associated with the catch optic providing for
the alignment of the catch optic with respect to a direction of the projection of the
multiplexed laser output to increase a quantity of laser light coupled to the catch side
optical fiber.
9. The sensing apparatus of claim 1 through 8 further comprising a pitch
side alignment mechanism providing for alignment of the pitch optic and adjustment
of the direction of the projection of the multiplexed laser output.
10. A method of sensing a combustion process comprising:
providing laser light at multiple select lasing frequencies;
multiplexing the laser light;
transmitting the multiplexed laser light in a pitch side optical fiber to a
process location;
projecting the multiplexed laser light through a combustion process;
receiving the multiplexed laser light in a catch side optical fiber;
demultiplexing the multiplexed laser light; and
transmitting a frequency of demultiplexed laser light to a detector.
46 AMENDED FAGE

11. The method of claim 10 further comprising determining a combustion
parameter from an output of the detector.
12. The method of claim 10 through 11 further comprising controlling the
combustion process in accordance with the determined combustion parameter.
AMENDED PAGE
47
A sensing apparatus consisting of more than one diode laser having select lasing frequencies, a multiplexer optically coupled to the outputs of the diode lasers with the multiplexer being further optically coupled to a pitch side optical fiber. Multiplexed laser light is transmitted through the pitch side optical fiber to a pitch optic operatively associated with a process chamber which may be a combustion chamber or the boiler of a coal or gas fired power plant. The pitch optic is oriented to project multiplexed laser output through the process chamber. Also operatively oriented with the process chamber is a catch optic in optical communication with the pitch optic to receive the multiplexed laser output projected through the process chamber. The catch optic is optically coupled to an optical fiber which transmits the multiplexed laser output to a demultiplexer. The demultiplexer demultiplexes the laser light and optically couples the select lasing frequencies of light to a detector with the detector being sensitive to one of the select lasing frequencies.

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01946-kolnp-2005-form 3.pdf

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Patent Number

223380

Indian Patent Application Number

01946/KOLNP/2005

PG Journal Number

37/2008

Publication Date

12-Sep-2008

Grant Date

10-Sep-2008

Date of Filing

30-Sep-2005

Name of Patentee

ZOLO TECHNOLOGIES, INC.

Applicant Address

4946 NORTH 63RD STREET, BOULDER, CO 80301

Inventors:

#	Inventor's Name	Inventor's Address
1	SAPPEY, ANDREW, D.	1845 TABOR STREET, LAKEWOOD, CO 80215
2	HOWELL, JAMES	542 HOPTREE COURT, LOUISVILLE, CO 80027 UNITED STATES OF AMERICA
3	HOFVANDER, HENRIK	126 GENESEE COURT, BOULDER, CO 80303 UNITED STATES OF AMERICA
4	MASTERSON, B., P.	325 WEST EISENHOWER DRIVE, LOUISVILLE, CO 80027 UNITED STATES OF AMERICA

PCT International Classification Number

G02B 6/00

PCT International Application Number

PCT/US2004/010048

PCT International Filing date

2004-03-31

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1	60/459,108	2003-03-31	U.S.A.