Formation of High-Temperature Minerals from an Evaporite-Rich Dust in Gas Turbine Engine Ingestion Tests

Abstract

The ingestion of multi-mineral dusts by gas turbine engines during routine operations is a significant problem for engine manufacturers because of the damage caused to engine components and their protective thermal barrier coatings. A complete understanding of the reactions forming these deposits is limited by a lack of knowledge of compositions of ingested dusts and unknown engine conditions. Testbed engines can be dosed with dusts of known composition under controlled operating conditions, but past engine tests have used standardized test dusts that do not resemble the composition of the background dust in the operating regions. New evaporite-rich test dust was developed and used in a full engine ingestion test, designed to simulate operation in regions with evaporite-rich geology, such as Doha or Dubai. Analysis of the engine deposits showed that mineral fractionation was present in the cooler, upstream sections of the engine. In the hotter, downstream sections, deposits contained new, high-temperature phases formed by the reaction of minerals in the test dust. The mineral assemblages in these deposits are similar to those found from previous analyses of service returns. Segregation of anhydrite from other high-temperature phases in a deposited sample taken from a high-pressure turbine blade suggests a relationship between temperature and sulfur content. This study highlights the potential for manipulating deposit chemistry to mitigate the damage caused in the downstream sections of gas turbine engines. The results of this study also suggest that the concentration of ingested dust in the inlet air may not be a significant contributing factor to deposit chemistry.