Effects of Sodium Vanadium compounds on Marine

Diesel engines
Fouling
A not uncommon failure of Marine diesel engines is a fouling of turbocharger nozzle rings and blades with
compounds containing sodium and vanadium as well as more traditional carbon deposits.
This leads to increased exhaust gas temperatures, loss of plant efficiency and reduced reliability. The
degree and type of fouling is dependent on the constituents and amounts of contaminants in the fuel oil.
Corrosion
More specifically high temperature corrosion directly caused by the presence of compounds of sodium and
Vanadium at temperatures over 5!".
#odium and Vanadium are found in heavy fuels up to $ppm and %ppm respectively
forming Vanadium &xides ' chiefly V$&5(, #odium oxidises to )a$& and with sulphur also contained,
sulphates )a#&* which are able to react further with vanadium oxides.
The various compounds that may be formed from these have a wide variety of properties one
of the most significant of which is the melting points
At the moment of solidification certain compounds can release molecular oxygen which can
attac+ the metal surface. &xygen may be re absorbed into the deposition thus forming an oxygen pump
which aggressively attac+s the surface of the metal during melting,solidification processes at around 5-
to %!". The iron oxide 'or )ic+el oxide for "r.)i #teels( diffuses into the melting ca+e. A typical reaction
is
)a$&.%V$&5 /.0 )a$&.V$&*.5V$&5 1 2,$ &$
The parts of most concern in marine diesels are 3xhaust valves, piston crowns as well as
components of the turbocharger such as the nozzle ring and blades.
Effects of ratio of Sodium and vanadium in fuel
Composition Melting Point
o
C
V$&5 %4
)a$&.V$&5 %5$
$)a$&.V$&5 %*-
)a$&.V$&*.5V$&5 5-5
5)a$&.V$&*.22V$&5 5-5
)a-6e'#&*(- 5*-
)a$#&* 554
6e$#&*(- 4$ 'decomposition(
6rom the table above it can be seen that the ratio of #odium to Vanadium in the compounds
greatly influences the melting point and thereby the corrosive and slagging effect.
The danger zone is ta+en to be Na/V ratio of 0.08 to 0.! of which 0."! to 0.#0 is particularly
destructive
Effects of $emperature and S%
&
The temperature of the components in the diesel engine will decisively influence the temperature at which
corrosion ta+es place. 7n addition the presence of #&$ causes the formation of sulphates in the melt
#&$ 1 V$&5 .0 #&- 1 V$&*
#&- 1 )a$& .0 )a$#&*
The sodium sulphate cannot exist in the melted #odium Vanadates and is released to further
attac+ the metal surfaces. The #&- may combine to form sulphurous deposits stripping protective oxide
layers from the metal surfaces.
'un(er )ualit* and t+e effects of Fuel Conditioning
A loo+ at a general cross section of the fuel oils being supplied around the world reveals that a significant
portion contain sodium and vanadium in ratios around that considered to be the most destructive.
8assing the fuel through a purifier was the effect of reducing the #odium content significantly
although there is little effect on the Vanadium content.
I have recently been in correspondence with an engineering manager of a large power generation
plant. His concern was that the fuel being supplied to the engines had a water content greater or
equal to 0.25%.
Water was being introduced into the fuel at an early stage of its conditioning as a method of washing
the sodium from the buners being supplied in an attempt to reduce the effects of sodium vanadium
corrosion.
Vanadium may be found in lubricating oil.
,lteration of t+e Na/V ratio
As mentioned careful purification can have a significant effect on the amount of #odium in the 6uel.
9owever #odium can be re.introduced into the combustion process in the form of salt water spray laden
air of due to lea+age of sea water cooled air coolers. 7t should be noted that where ratios are e:uivalent
corrosion processes were the sodium was already contained in the fuel are significantly higher.
3ven when )a,V ratios are out of the danger zone it is possible for poc+ets or !ban+s! of
products to build up and be released to form these damaging ratios. Typically #odium deposits may be
found in the scavenge areas and #odium and Vanadium deposits in the exhaust areas.
Fuel additivies
Magnesium salt based additives are available on the mar+et. The effect of these is to increase the melting
point of the compounds formed. deposits tend to be loose and easily removed and little corrosion may be
evident
-ecommendations
An exhaust gas temperature of 5- to 5%!" and )a,V ratios of .25 to .- are the danger zones. 6or
reasons described it is very difficult to avoid these ratios, however the following recommendations are
given which should significantly reduce corrosion and could possibly influence the degree of slagging.
Use fuels with sodium vanadium ratios outside the critical zone of 0.15 to 0.30 and preferably
0.08 to 0.45
Ensure efficient separation to reduce sodium content
eep mean e!haust "as temperatures below 500#$ and turbochar"er inlet temperature below
530#$
Ensure that demisters are operatin" properly and cure sea water lea%s in coolers.
Use &" salt based fuel additives
6urther ;eading<
Mechanisms of 9igh Temperature "orrosion in Turbochargers of Modern 6our #tro+e Marine
3ngines<Motoren und 3nergietechni+ =Mbh ;ostoc+