DOE/MC/25 140-96/C0560

The Power Systems Development Facility - Current Status

Authors:

Timothy E. Pinkston J. Douglas Maxwell

Roxann F. Leonard Pannalal Vimalchand

Con tractor:

Southern Company Services, Inc. Power Systems Development Facility P.O. Box 1069 Highway 25 North Wilsonville, Alabama

Contract Number:

DE-FC21-9OMC25140

Conference Title:

EPRI Conference on New Power Generation Technology

Conference Location:

San Francisco, California

Conference Dates:

October 25-27, 1995

Conference Sponsor:

Electric Power Research Institute (EPRI)

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THE POWER SYSTEMS DEVELOPMENT FACILITY-CURRENT STATUS

Timothy E. Pinkston, J. Douglas Maxwell, Roxann F. Leonard, Pannalal Vimalchand Power Systems Development Facility

Southern Company Services, Inc., P.O. Box 1069, Wilsonville, AL 35186

EPRI Conference on New Power Generation Technology San Francisco, October 25-27, 1995

Abstract

Southern Company Services, Inc. (SCS) has entered into a cooperative agreement with the U.S. Department of Energy (DOE) to build and operate the Power Systems Development Facility (PSDF). In addition to DOE and SCS, the Electric Power Research Institute is a co-fbnder. Other co-funding participants supplying services or equipment include The M. W. Kellogg Company, Foster Wheeler USA, Westinghouse, Industrial Filter & Pump, Combustion Power Company and Nolan Multimedia. The PSDF is currently under construction in Wilsonville, Alabama, 40 miles southeast of Birmingham. The objectives of the PSDF are to develop advanced coal-fired power generation technologies through testing and evaluation of hot gas cleanup systems and other major components at the pilot scale. The performance of components will be assessed and demonstrated in an integrated mode of operation and at a component size readily scaleable to commercial systems. The facility will initially contain five modules: (1) a transport reactor gasifier and combustor, (2) an advanced pressurized fluidized-bed combustion (APFBC) system, (3) a particulate control module, (4) an advanced burner-gas turbine module, and (5) a fie1 cell. The five modules will initially be’configured into two separate test trains, the transport reactor train ( 2 tonshour of coal feed) and the APFBC train ( 3 tonshour of coal feed). In addition to a project description, the project design and construction status, preparations for operations, and project test plans are reported in this paper.

Background Information

The Power Systems Development Facility (PSDF) located at Wilsonville, Alabama will be the focal point for much of the Nation’s advanced coal-fired electric power technology development in the latter 1990s and into the 21st century. Coal will supply at least halfthe Nation’s electricity well into the 21st century (it currently accounts for 56%). Yet, ikture coal systems will have to be increasingly cleaner and more efficient ifthe United States is to use its most abundant fossil fuel to sustain economic growth.

Jointly sponsored by the Department of Energy (DOE) and many of the Nation’s most forward- looking power equipment developers, the PSDF will be a highly flexible modular test center. Equipment developers will be able to test innovative electric power system components--new

combustors, improved cleanup systems, and advanced turbines and fuel cells--at a central location, saving the time and expense of building separate test facilities.

Plans call for the facility to contain five modules initially: (1) an advanced pressurized fluidized- bed combustion (APFBC) system, (2) a transport reactor gasifier and combustor, (3) a particulate control module, (4) an advanced burner-gas turbine module, and (5) a fuel cell. Combining these modules into a single structure has saved more than $32 million when compared to the cost of building stand-alone facilities.

Hardware systems can first be evaluated separately, then linked together in an integrated power system. Filters can be tested with a pressurized fluidized-bed combustor or with a coal gasifier. Advanced turbines and fuel cells can be tied into the process path in a variety of ways. The facility will be capable of operating at pilot to near-demonstration scales, large enough to give industry real-life data for scaleup to commercial size, yet small enough to be cost-effective and adaptable to a variety of industry needs.

DOE is providing 80 percent of the finding with industry cost sharing 20 percent. The project team comprises DOE, Southern Company Services, Inc. (SCS), the Electric Power Research Institute (EPRI), Foster Wheeler 0, The M.W. Kellogg Company (&€WK), Westinghouse, Industrial Filter & Pump (IF & P), Combustion Power Company, Nolan Multimedia, and Southern Research Institute (SRI). SCS Research and Environmental Affairs is managing the overall project and procuring the particulate control devices (PCDs). The design of the facility as well as balance-of-plant design and plant layout is being coordinated by SCS Engineering. SCS also is providing construction management and will operate the facility with a site staff of about 90 people. The process engineering and detail design for the transport reactor gasifier and combustor is provided by MWK. FW is performing the process engineering and detail design for the APFl3C module and has the lead in integrating with the advanced burner-gas turbine module. EPRI is providing technical guidance to the project in addition to cost sharing. Southern Research Institute will evaluate PCD performance by conducting particulate and alkali sampling. The other participants supply services or equipment to the project and are also co-fhders.

Objectives

The objectives of the PSDF are to develop advanced coal-fired power generation technologies through the testing and evaluation of hot gas cleanup systems and other major components at the pilot scale and to assess and demonstrate the performance of the components in an integrated mode of operation and at a component siie readily scaleable to commercial systems.

The primary focus of the PSDF project is to demonstrate and evaluate high temperature PCDs which are the single most important component required for successfid development of advanced power generation systems. High temperature PCDs are a common component of advanced gasification and APFBC technologies, both of which will be evaluated at the facility. Successfbl high temperature gas cleanup will increase the efficiency and reduce the capital and operating costs of coal gasification processes by avoiding cooling and reheating of the syngas as is required in current technology. APFBC processes also benefit fiom the use of high-temperature PCDs

which allow the use of modem high efficiency gas turbines instead of ruggedized expander turbines. A recent engineering and economic evaluation by EPRI indicates that the capital cost of ABB-Carbon's bubbling PFBC can be reduced by as much as 9% when a PCD is used in conjunction with a non-ruggedized gas turbine.'

Project Description

Initially, the five modules at the PSDF will be configured into two separate test trains as shown in the process schematic in Figure 1. The transport reactor train will be used to produce a particle- laden gas for testing of two of the PCDs. The APFBC module will be integrated with the topping combustor and gas turbine for long term testing of the PCDs in an integrated system and assessment of the control and integration issues associated with the APFBC system.

Advanced Gasifier

The M.W. Kellogg transport reactor technology under development at the PSDF at a scale of about 2 tons/ hour of coal can operate either as a gasifier or as a PFBC unit. A simplified process flow diagram for the transport reactor system is shown in Figure 2. Tests will be conducted in . both configurations. In the gasifier mode, coal is introduced and fired substoichiometrically. The coal devolatilizes, the volatiles pyrolie and the residual char is steam gasified. This staging of the gasification reaction forces oxygen to react with char rather than volatiles, as is characteristic in fluid bed gasifiers. As a result, the size of the gasifier (and the capital cost) is reduced because the amount of char to be gasified by reaction with steam (which is quite slow) is reduced substantially. Operation in the circulating PFBC mode is similar, but the reactor is fired with excess air?

Advanced PFBC

APFBC continues to emerge as a viable coal-based advanced power generation technology in the utility industry for both repowering and new plants. First generation PFBC technology offers the advantages of being more compact and efficient, compared to pulverized coal units, and has a simpler design than most advanced power generation systems. However, first generation PFBC systems have limited efficiency due to low temperature operation and the use of ruggedized turbines. To improve efficiency, PFBC systems must employ hot particulate removal and a topping cycle in order to use advanced turbine designs. These second-generation APFBC designs are expected to be capable of achieving 45% net plant efficiency. Advancing the development of APFBC systems is one of the primary goals of the PSDF.

At a scale of 3 tonsh, the Foster Wheeler APFBC system under development at the PSDF (see Figure 3) utilizes a topping cycle. It is a hybrid system that combines partial gasification with PFBC. Coal is first fed to a pressurized carbonizer, where it is converted to a low-Btu &el gas and char. The char produced in the carbonizer is transferred to a circulating PFBC (CPFBC) where it is subsequently burned. Sul&r is removed in the process by the addition of limestone into the carbonizer and CPFBC. The carbonizer &el gas and CPFBC flue gas are cleaned of

I

particulates in separate ceramic filters, after which the he1 gas is fired in a specially designed topping combustor outside a high-temperature gas turbine using the CPFBC flue gas as the oxidant.

Multiannular Swirl Burner (MASB)/Turbine

The APFBC plant at the PSDF will provide the first operation of a gas turbine and topping combustor with hot pressurized fuel gas from the carbonizer and hot pressurized flue gas from the APFBC. Periodic examination of the gas turbine will allow the merits of hot gas cleanup for APFBC systems to be evaluated. '

Particulate Control Devices

At the PSDF, four different PCDs will be evaluated initially. Industrial Filter & Pump Mfg. Co. @&P) will supply one PCD that will be tested initially on the Carbonizer fie1 gas fiom the FW APFBC train. The IF&P device will contain ceramic (Fibrosic) candles and a ceramic tubesheet, but the design is flexible to allow the use of alternate elements as backup. The IF&P PCD is sized to match the gas flow requirements fiom the MWK transport reactor and can be moved to the transport reactor for testing at a later date.

Westinghouse will provide two PCDs. One will initially be tested on the MWK transport reactor and is interchangeable with the IF&P device on the FW APFBC process. This Westinghouse PCD, will be capable of operating with several types of filter elements, but the initial configuration will use candle filters. The FW APFBC system requires two PCDs. The second Westinghouse PCD for the combustor in the APFBC system will use mullite candle filter elements, but will not be interchangeable with other PCDs at the facility.

The fourth PCD is a moving, granular bed filter to be supplied by Combustion Power Company (CPC). This PCD is sized to be interchangeable with the IF&P PCD installed on the APFBC system, but because of its substantially different configuration, is not expected to be tested on the Foster Wheeler unit.

Fuel Cell

A fie1 cell is scheduled for integration with the advanced gasifler during the second year of operation after stable operation of the system is assured. The he1 cell will be connected to the advanced gasifier downstream of the PCD and the secondary gas cooler. This Integrated GasificatiordFuel Cell (IGEC) system will be the first to operate with a hot gas cleanup system. IGRC systems have the potential of achieving system efficiencies above 55% with extremely low emissions.

Project StatudSchedule

The project schedule and the major tasks are shown in Figure 4. The major activities during the past year have been the final stages of design, procurement of major equipment and bulk items,

construction of the facility, and the preparation by the O&M stafF for operation of the facility in late 1995.

Design

The process design was predominantly completed by the summer of 1994. A detailed description of the process design was presented in two previous papers at the DOE Advanced Coal-Fired Power Systems Conference3 and a detailed description of the PCDs also appears elsewhere5. M.W. Kellogg completed the design for the transport reactor system in December 1994 and Foster Wheeler is scheduled to complete the design of the Advanced PFBC system in September of 1995. The balance-of-plant (BOP) design is scheduled for completion by Southern Company Services in September of 1995.

A Design Hazard Review (DHR) was completed for the transport reactor systems in 1994. The DHR for the BOP has been completed for that portion of the design prepared by Southern Company Services. The remainder of the BOP DHR will be completed in September 1995 after all final equipment vendor drawings are received.

The objective of the DHR was a qualitative assessment of the design using a structured format and methodology. The specific methodology for the reviews conducted used the “What-if’ technique augmented by a guide-word checklist and was performed in accordance with the guidelines published by the American Institute of Chemical Engineers Center for Chemical Plant Safety. The review systematically examined design documentation in order to identie potential hazards and major operability problems in the facility which could compromise the ability of the systems and equipment to safely handle start-up and credible operating deviations from the design intent. The findings of the DHR were reviewed in detail and incorporated into the design as necessary.

Construction

Site preparation was completed in January 1994. Installation of underground pipes and conduits began in July 1994 and was complete by November 1994 except for some miscellaneous connections.

Erection of structural steel began in November of 1994 when work began on the structure to house the coal and limestone storage bins and mills for sizing the coal and limestone. Erection of the main process structure began in December 1994. The main process structure is five bays wide by three bays deep with the two outside bays on one side housing the APFBC system and the two outside bays on the other side housing the transport reactor system; the center bays between the two systems provide a buffer and access for maintenance. Erection of the steel to the top elevation (190 feet above grade) has been completed for the transport reactor and center bays. Erection will be completed in early October for the two APFBC System bays. Equipment is being placed as the structure is built.

All of the major equipment for the transport reactor system has been placed in the structure and

in October and these activities will proceed in parallel with the final construction activities. The first coal feed is targeted for December 1995.

completion of the system construction is expected in December 1995. Commissioning will begin

Completion of the APFBC System construction is expected in March 1996 and “hot shakedown’, in the simple-cycle mode will begin in May of 1996. M e r commissioning the topping combustor, the first coal feed to the APFBC system is planned for the second quarter of 1996.

Buildings housing the warehouse, maintenance shop, on-site laboratory, offices and control room are complete, and the O&M and the research staffmoved to the site in April 1995.

Preparation for Operation

Southern Company Services personnel will be responsible for operation of the PSDF. The operations manager and maintenance supervisor were assigned to the project in the last quarter of 1994. Operations shift coordinators and the remainder of O&M supervisory personnel were assigned to the project beginning in March 1995. The O&M staff is currently developing detailed operating manuals and maintenance procedures and setting up the maintenance shop. Operators, mechanics, and instrument technicians for the transport reactor system were assigned to the project in August of 1995. Alabama Power Company, a subsidiary of the Southern Company, provided the PSDF well-trained and experienced operators and mechanics. Having been trained on the specifics of the PSDF technologies, the operators and maintenance technicians will assist in final preparation of the operating and maintenance manuals and begin commissioning activities on the transport reactor system and balance-of-plant equipment.

Work started in the fall of 1994 on-developing a commissioning sequence that would logically order the equipment start-up testing and commissioning to allow significant pre-operational milestone tests and activities to occur before construction is complete on the entire process train and balance-of-plant equipment. The commissioning schedule identified components that need to be operational to complete each milestone activity. The commissioning schedule was integrated with the existing project engineering and construction schedule.

Electrical equipment (breakers, relays, motor starters) is being tested by construction and engineering personnel as it is installed. All testing is being completed as early as possible to identifl and correct any problem associated with equipment, before it could impact the process start-up date.

PSDF Experimental Test Program

The critical issues to be addressed include the integration of PCDs into coal utilization systems, on-line cleaning techniques, chemical and thermal degradation of components, fatigue or structural failures, blinding, collection efficiency as a function of particle size, and scale-up to commercial-size systems. To facilitate the assessment of the PCDs, it is critical that the test conditions, such as gas temperature and particle loading, be variable over a range of values.

Long-term endurance tests will involve about 1000 hours of continuous PCD operation at nominally constant operating conditions. The goals of these tests are to demonstrate integration of the PCDs into advanced power generation systems, assess the long-term durability of the PCDs, demonstrate durable candle materials, and evaluate load cycling effects on the PCDs.

In addition to being a resource for performance assessment of hot stream cleanup devices, the PSDF has been designed as a flexible test facility that will be used to test and optimize the operation of advanced power system components, such as the transport gasifier/combustor, and' advanced topping combustor and turbine as well as fuel cell system configurations. Testing planned for the PSDF will also focus on issues related to integration of several advanced power system components as part of an entire power generation train. The MWK transport reactor for the PSDF represents a novel design for a gas source, and the test plan will address the operation and characterization of the reactor as well as the behavior of the PCDs selected for testing with the transport reactor. Similarly, the test plan will also address the control issues associated with the operation of the F W APFBC train with PCDs integrated into the system.

MKK Train. A detailed test plan and schedule was completed in July. The schedule is shown in Figure 5. Most of the parametric testing will.be done using the transport reactor system, since the APFBC system is integrated with a gas turbine and is less flexible in terms of the PCD operating conditions. The transport reactor will be operated as both a combustor and a gasifier to allow PCD testing in both modes of operation.

Cold shakedown of the transport reactor system and the PCDs will begin in October 1995. Hot shakedown and combustion mode characterization testing will follow with the Westinghouse PCD in service. Next, the CPC PCD will be placed in service for characterization testing. When combustion mode characterization testing has been completed, there will be a hot shakedown in the gasification mode, however it will require only a short time since the suifator will be the only new equipment. There will be gasification mode characterization tests with both the Westinghouse PCD and CPC PCD next.

With systems proven operational and characterized, performance tests will start around mid-June, 1996. Test campaign 1 will be subdivided into ten 80 hour test periods and run in the combustion mode with the Westinghouse PCD in service. Alabama bituminous coal and dolomite will be used with a short limestone test at the end of the campaign. The PCD inlet temperature will be around 1300°F with gas loadings fkom 4,000 to 10,000 ppmw.

The temperature of the gases leaving the transport reactor can be lowered using a gas cooler, allowing for a range of PCD inlet temperatures. In view of reported problems with the thermal shock of the ceramic filter elements, the initial PCD testing will be done at 1,000-1,3OO0F, and then gradually increased as experienced is gained in operating the PCDs.

The range of operating conditions for parametric and long-term testing of the PCDs for the MWK transport reactor is given in Tables 1 and 2.

Test Campaign 2, divided into ten 100 hour test periods, will be in the gasilkation mode with the Westinghouse PCD in service. Powder River Bash (PRB) subbituminous coal and Alabama bituminous coal will be tested with both dolomite and limestone. Met PCD temperatures will be set at 1000°F and 120OOF with gas loadings varying fiom 4,000 to 12,000 ppmw.

Test Campaign 3, also ten 100 hour test periods, will be in the combustion mode with the CPC PCD. Again, PRB subbituminous coal and Alabama bituminous coal will be used with both dolomite and limestone. The full range of PCD loadings will be tested at 1300OF. Test Campaign 4 will be similar to Test Campaign 3 except it will be in the gasification mode with inlet PCD temperatures around 1600°F.

Test Campaign 5 will be a combustion mode test with the IF&P PCD in service at an inlet temperature around 1300OF. Testing will be with Alabama bituminous coal and an alternate high sulfbr bituminous coal with both dolomite and limestone. Test Campaign 6 will be a gasification mode test with conditions similar to Test Campaign 2 & 4.

The granular bed filter performance will be assessed by gathering inlet and outlet dust loading data at full- and part-load test conditions to determine the effect of reactor process variables (filtration gas velocity, inlet dust loading and size distribution, depth of flter media, media circulation rates, and media sizes) upon dust collection efficiency. The performance data will be compared with tests conducted previously at New York University to assess the effect of scale-up. The Westinghouse filter performance will similarly be assessed by determining how dust collection efficiency and filter cake removal is influenced by filtration gas velocity, inlet dust loading, inlet dust size distribution, load change and pulse parameters including pulse gas pressure and pulse fiequency.

As tests with the filters are being performed, the transport reactor performance will be determined as a function of process variables and load conditions. The reactor performance indicators to be monitored include combustion and sulfbr retention efficiencies, heat transfer rates to all cooling su~aces, alkali emissions before and after the flue gas cooler, NO, emissions, CO emissions, flue gas dust loadings leaving the cyclone, and the dynamic response rate of the reactor to changes in temperature, CdS molar ratio, and to simulated load changes.

FW Train. An outline of the test plan for the APFBC was completed in July 1995 and the detailed test plan and schedule will be completed in the last quarter of 1995. The APFBC design operating conditions are given in Table 3.

Summary

Advanced generation technologies must offer improved energy conversion efficiency and low costs to be viable options for new plant and existing facility repowering sources of electrical generation. The PSDF provides an opportunity to develop such advanced coal-fired power generation technologies through the testing and evaluation of hot gas cleanup systems and other major components at the pilot scale while demonstrating the performance of the components in an integrated mode of operation. The primary focus of the PSDF project is to demonstrate and evaluate high temperature gas cleanup systems. Hot gas cleanup systems are a common component of advanced gasification and APFBC, both of which will be evaluated at the facility. Successhl high temperature gas cleanup will increase the efficiency and reduce the capital and operating cost of coal gasification processes by avoiding cooling and reheating of the syngas which is required in current technology. APFBC processes also benefit fiom the use of hot gas cleanup devices which allow the use of modern high efficiency gas turbines instead of ruggedized expander turbines.

The PSDF design is essentially complete and construction is underway. Steel erection is over 75% complete. Major equipment is being placed in the structure as it is being erected. Completion of construction of the MWK train is scheduled for December 1995 with the first coal feed to the system targeted for December 1995. Construction of the F W train is scheduled for completion by March 1996 with the first coal feed to the system to follow “hot shakedown” which is planned to begin in May 1996. Testing on both trains is planned through 1997.

References

1. J.M. Wheeldon, et al, “An Engineering and Economic Evaluation of High Temperature, High Pressure Filtration Applied to Bubbling PFBC Power Plant Design,” to be presented at EPN Conference on New Power Generation Technology, San Francisco, CA (October 25-27, 1995).

2. W.M. Cambell, “Transport Reactor Development Status”, prepared for Coal-Fired Power Systems 94 METC Contractor’s Conference, Morgantown, WV (June 21-23, 1994).

3. R.E. Sears, et al, “Power Systems Development Facility, PFBC System Perspectives”, presented at Coal-Fired Power Systems 93 Conference at DOE/METC (June 28-30, 1993).

4. D.L. Moore, et al, “Status of the Advanced PFBC at the Power Systems Development Facility”, presented at Coal-Fired Power Systems 94 Conference DOE/METC (June 21-23, 1994).

5. P. Vimalchand, et al, “The DOE/SCS Power Systems Development Facility” presented at the Twelfth E P N Annual Conference on Gasification Power Plants, San Francisco, CA (October 27-29, 1993).

HOT GAS

SULFUR AND ASH

GAS COMBUSTOR

ULFURANDASH

PRESSURIZED

Figure 1. Simplified Process Diagram of the PSDF

Figure 2. M.W. Kellogg Advanced Gasifier Train

LIMESTONE

i u i BARREL

Figure 3. Foster Wheeler APFBC Train

Figure 4. Program Schedule

3ct ~NOV~DOC 1991 1997-

Jan IFeblMarl AprlMaylJunl Jul IAuglSwl Oct lNwlDbo Jin IFeblMar t Apr lMayl Jun I Jut lAuglSopl Oct lNovlDrc task Ninw COMBUSTION MODE

Duration Ow

CPC PCD 8w

Fuel Cell s2w

ID 1 -

2 I Cold & Hot Shakedown

Character1,zation Tests 1 :; Wesl.PCD

3

4

6

-

Performance Tests ,-I,, 6

7 west.^^^ I :1

8 TC3 I 13w CPC PCD

9

10

11

12

- - -

TC5 I 12w IFLPPCD I 3. c 2 I GASIFICATION MODE

I .low Characterization Tests -

West. PCD 13

I 6w CPC PCD 14

16

16

17

- Performance Tests

,-;XI + West. PCD 1 C1,C3 I fCPC PCD

IFLPPCD I 18 TC6 I 12w I

A -I\ 19 Fuel Cell

C l -Alabama bltumlnous coal (1-1.2 % S) C2 - Alternate bltumlnous coal (3 %S) C3 - PRB subbltumlnous coal

Table 1 MWK Combustion Mode Variables

Variable Coal feed rate. lb/hr

Alabama bituminous PRB subbituminous

Coal Feed Size (geometric mean) CdS molar ratio

Dolomite Limestone

Reactor temperature, OF Reactor pressure, psia Excess air, % Staged air split, % (primaryhecondary) Primary air split (1 st/2nd levels) Riser gas velocity, fix PCD inlet conditions

TemPerature. O F Pressure, psia Particulate loading, ppmw Gas flow rate- ACFM

Low Design High

Dartload I 1604 I fillload I part load 1668 fill load 100 100 coarse

1.33 1.5 3 1.33 1.5 1.58 1500 I 1600 I1600 I 160 I 160-310 I310 I 10 I 1 5 I 40 I 70/40 I 80/30 I 110/0 40/60 50/50 60/40 0.9 x design design 1.1 x design

1000 1000-1525 1525 I I

160 I 160-310 I310 1 4,000 4,000-10,000 10,000 861 1000 1-385

Table 2 MWK Gasification Mode Variables

Variable Coal feed rate. lb/hr

Low Design High

Alabama bituminous I Dart load I 3124 I fill load

TemDerature. OF I 1200 11200-1700 I1700 Pressure, psia 179 179-255 255 Particulate loading, ppmw 4,000 4,000-16,000 16,000 Gas flow rate. ACFM 893 1000 1-100

Table 3 Design Conditions for Foster Wheeler Advanced PFBC Train

Design coal feed rates, Ibsh Alabama bituminous 5.550

I PRB sub-bituminous I 6.450 I Coal top size, inches Design sorbent feed rates, lbsh

Dolomite and limestone

118

1.050 I C ~ / S molar ratio for 95% ret’n I 2.0 I

Sorbent top size, inches Carbonizer design conditions

Pressure. Dsia

118 -

175 I Temperature, O F I 1,700 1

Pressure, psia Temperature, OF

I Combustor design conditions I I 165

1,600 Inlet loading to PCDs, ppmw 10,000