<p>To investigate the corrosion behavior and mechanisms of 3Cr steel under high-salinity, high-Ca<sup>2+</sup>, and O<sub>2</sub>–CO<sub>2</sub> conditions, we simulated the service environment of a western China oilfield (total salinity 250,022&#xa0;mg/L, Ca<sup>2+</sup> &gt; 15,400&#xa0;mg/L). Immersion and electrochemical tests were conducted at 120&#xa0;°C under 0.5&#xa0;MPa CO<sub>2</sub> with O<sub>2</sub> partial pressures from 0 to 0.4&#xa0;MPa. The results showed that the uniform corrosion rate increased sharply from 0.6492&#xa0;mm/a in pure CO<sub>2</sub> to 4.8551&#xa0;mm/a at 0.4&#xa0;MPa O<sub>2</sub>, with localized corrosion notably aggravated. It was found that the high Cl<sup>−</sup> concentration acted as a crystallization inhibitor, forcing the FeCO<sub>3</sub> corrosion product into an amorphous state. In pure CO<sub>2</sub>, the corrosion film displayed a multilayered architecture: a surface crystalline CaCO<sub>3</sub> layer with micropores exhibiting inward/outward growth, an intermediate amorphous FeCO<sub>3</sub> layer, and an inner amorphous Cr-rich oxide layer. This structure was governed by the kinetic dominance of Ca<sup>2+</sup>, which preferentially precipitated as CaCO<sub>3</sub>, thereby suppressing FeCO<sub>3</sub> growth through interfacial competition and localized acidification. With O<sub>2</sub> introduction, the synergistic effect of O<sub>2</sub>, Ca<sup>2+</sup>, and Cl<sup>−</sup> triggered the formation of a loose, porous Fe<sub>2</sub>O<sub>3</sub>/CaCO<sub>3</sub> composite scale. Notably, 3Cr steel exhibited a weak deposition behavior of CaCO<sub>3</sub> because of both the lower deposition tendency and adhesion strength of CaCO<sub>3</sub> on the amorphous Cr-rich layer. This structural deficiency led to non-uniform film coverage and generated a “small-anode/large-cathode” configuration, accelerating lateral pitting propagation. Although the dense Cr-rich layer effectively hindered Cl<sup>−</sup> penetration into the substrate, it cannot prevent the expansion of acidified occluded cells. These findings elucidate the synergistic effects of O<sub>2</sub>–CO<sub>2</sub>–Cl<sup>−</sup>–Ca<sup>2+</sup> on 3Cr steel corrosion and provide a theoretical basis for material selection and protection of tubing steels in oxygenated, high-salinity oil and gas wells.</p>

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Corrosion behavior and mechanisms of 3Cr steel in a high-salinity O2–CO2 environment

  • Hangbo Hu,
  • Yanming Liu,
  • Minlu Shi,
  • Mingwei Yao,
  • Xianghong Lü,
  • Pan Dai

摘要

To investigate the corrosion behavior and mechanisms of 3Cr steel under high-salinity, high-Ca2+, and O2–CO2 conditions, we simulated the service environment of a western China oilfield (total salinity 250,022 mg/L, Ca2+ > 15,400 mg/L). Immersion and electrochemical tests were conducted at 120 °C under 0.5 MPa CO2 with O2 partial pressures from 0 to 0.4 MPa. The results showed that the uniform corrosion rate increased sharply from 0.6492 mm/a in pure CO2 to 4.8551 mm/a at 0.4 MPa O2, with localized corrosion notably aggravated. It was found that the high Cl concentration acted as a crystallization inhibitor, forcing the FeCO3 corrosion product into an amorphous state. In pure CO2, the corrosion film displayed a multilayered architecture: a surface crystalline CaCO3 layer with micropores exhibiting inward/outward growth, an intermediate amorphous FeCO3 layer, and an inner amorphous Cr-rich oxide layer. This structure was governed by the kinetic dominance of Ca2+, which preferentially precipitated as CaCO3, thereby suppressing FeCO3 growth through interfacial competition and localized acidification. With O2 introduction, the synergistic effect of O2, Ca2+, and Cl triggered the formation of a loose, porous Fe2O3/CaCO3 composite scale. Notably, 3Cr steel exhibited a weak deposition behavior of CaCO3 because of both the lower deposition tendency and adhesion strength of CaCO3 on the amorphous Cr-rich layer. This structural deficiency led to non-uniform film coverage and generated a “small-anode/large-cathode” configuration, accelerating lateral pitting propagation. Although the dense Cr-rich layer effectively hindered Cl penetration into the substrate, it cannot prevent the expansion of acidified occluded cells. These findings elucidate the synergistic effects of O2–CO2–Cl–Ca2+ on 3Cr steel corrosion and provide a theoretical basis for material selection and protection of tubing steels in oxygenated, high-salinity oil and gas wells.