目的 CCUS-EOR工程实践中井筒管材J55钢多次发生垢下腐蚀失效穿孔。为明确饱和CO2环境中J55钢垢下腐蚀作用机理,揭示腐蚀产物膜演化和电化学行为间的内在联系,阐明垢层覆盖下金属溶解的电化学动力学及全生命周期的腐蚀演化机制。方法 本研究通过丝束电极技术、电化学阻抗谱和电化学噪音,联合表面分析技术,系统研究了J55钢在饱和CO2模拟油田采出水环境中的腐蚀产物膜成分、垢层破损后基体区域电偶腐蚀行为及局部腐蚀电化学时空演化特征。结果 J55钢腐蚀过程表现出明显的阶段性,且受腐蚀产物膜性质的影响显著。腐蚀初期,表面生成的FexCa1-xCO3膜层疏松多孔,加速了基体金属的腐蚀;随着浸泡时间延长,基体溶解产生的Fe2+与垢层孔隙中的CO32-发生反应,生成致密的FeCO3晶体填充于垢层内,显著提升了膜层的阻隔性能,腐蚀速率随之降低。当垢层发生局部破损时,裸露金属区与垢层覆盖区形成电偶效应,并在破损交界处表现出最严重的腐蚀倾向。结论 垢层下金属受电偶腐蚀和局部腐蚀的耦合作用,且裸金属区域与垢层覆盖区域的交界处腐蚀最为严重,长时间腐蚀后垢层下金属最终从局部腐蚀转变为均匀腐蚀。
Abstract
Under-deposit corrosion (UDC) presents a critical threat to the integrity of J55 steel wellbore tubes during Carbon Capture, Utilization and Storage (CCUS) enhanced oil recovery operations. While the qualitative effects of deposits are recognized, the transient electrochemical evolution and spatial correlation of UDC throughout its entire life cycle remain poorly understood at the microscopic scale. The work aims to provide a comprehensive investigation of the electrochemical kinetics and spatial-temporal evolution of UDC on J55 steel in saturated CO2-produced water through advanced wire beam electrode (WBE) technology, electrochemical impedance spectroscopy (EIS), and electrochemical noise (EN) analysis. To decouple the complex interactions between varying surface conditions, a multidimensional experimental framework was established. A 10×10 WBE matrix, with a 50% coverage ratio, was specifically utilized to replicate localized scale damage. This setup enabled, for the first time, the high-resolution mapping of galvanic current density and potential distribution between bare metallic surfaces and scale-covered regions. Unlike conventional immersion tests, this approach allowed for the capture of the site-specific transition from initiation to steady-state corrosion. The electrochemical evolution was further complemented by characterizing the phase composition and morphology of the corrosion product layers with XRD and SEM. Experimental findings revealed that the corrosion of J55 steel was governed by the structural transformation of the FexCa1-xCO3/FeCO3 film. In the initial phase (0-24 h), the formation of relatively loose and porous FexCa1-xCO3 crystals significantly exacerbated the corrosion of the underlying substrate. A sharp increase in galvanic current density, peaking at 5.2×10-7 A/cm2, was recorded at the interface, confirming the initiation of a macro-galvanic cell due to the difference in local environment chemistry. A pivotal discovery of this work was the mechanism of "polarity reversal" observed at 6 h of immersion, where the scale-covered region shifted from a cathodic protector to a sacrificial anodic site, driven by the acidification of the under-deposit micro-environment and the hindered diffusion of iron ions. The EN analysis, processed through both Fourier Transform and wavelet transform, provided a mechanistic breakdown of the pitting evolution. During the transition phase (6-36 h), the energy distribution in the medium-frequency band (0.01-0.1 Hz) escalated, signaling rapid metastable pitting growth. The calculation of the PSD linear slope (K) provided quantitative evidence, with a transition from values > -20 dB/decade (indicating unstable local corrosion) to < -20 dB/decade as the FeCO3 layer reached a state of relative passive stability. By 48 h, the filling of voids within the initial porous film by more compact FeCO3 crystals acted as a self-healing kinetic barrier, effectively suppressing the pitting frequency. Finally, after 72 h, the corrosion regime underwent a fundamental transformation from active pitting to a suppressed uniform corrosion state, as confirmed by the damping of high-frequency potential transients. This work demonstrates that the service life of J55 steel is strictly limited by the competitive growth kinetics of the Fe-Ca carbonate films. The results establish that the coupling of interfacial galvanic effects and internal acid-induced pitting is the primary mechanism of premature failure. These insights bridge the gap between microscopic electrochemical phenomena and macroscopic failure modes, offering a robust theoretical foundation for developing proactive corrosion monitoring techniques and failure prediction models for CCUS-related infrastructure.
关键词
J55钢 /
CO2腐蚀 /
垢下腐蚀 /
丝束电极 /
电化学噪声
Key words
J55 steel /
CO2 corrosion /
under-deposit corrosion /
wire beam electrode /
electrochemical noise
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基金
国家重点研发计划资助（2023YFF0614100）; 中国石油天然气集团有限公司科技项目（2025DJ106）; 中国石油天然气股份有限公司科学研究与技术开发项目（2021ZZ01-04）
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