diff --git a/crates/zclaw-saas/src/main.rs b/crates/zclaw-saas/src/main.rs
index e4d8095..92eca44 100644
--- a/crates/zclaw-saas/src/main.rs
+++ b/crates/zclaw-saas/src/main.rs
@@ -99,6 +99,8 @@ async fn main() -> anyhow::Result<()> {
             if let Err(e) = zclaw_saas::crypto::migrate_legacy_totp_secrets(&db, &enc_key).await {
                 tracing::warn!("TOTP legacy migration check failed: {}", e);
             }
+            // Self-heal: re-encrypt provider keys with current key
+            zclaw_saas::relay::key_pool::heal_provider_keys(&db, &enc_key).await;
         } else {
             drop(config_for_migration);
         }
diff --git a/crates/zclaw-saas/src/relay/key_pool.rs b/crates/zclaw-saas/src/relay/key_pool.rs
index 4f6267a..3718548 100644
--- a/crates/zclaw-saas/src/relay/key_pool.rs
+++ b/crates/zclaw-saas/src/relay/key_pool.rs
@@ -117,7 +117,13 @@ pub async fn select_best_key(db: &PgPool, provider_id: &str, enc_key: &[u8; 32])
         }
 
         // 此 Key 可用 — 解密 key_value
-        let decrypted_kv = decrypt_key_value(key_value, enc_key)?;
+        let decrypted_kv = match decrypt_key_value(key_value, enc_key) {
+            Ok(v) => v,
+            Err(e) => {
+                tracing::warn!("Key {} decryption failed, skipping: {}", id, e);
+                continue;
+            }
+        };
         let selection = KeySelection {
             key: PoolKey {
                 id: id.clone(),
@@ -371,3 +377,52 @@ fn parse_cooldown_remaining(cooldown_until: &str, now: &str) -> i64 {
         _ => 60, // 默认 60 秒
     }
 }
+
+/// Startup self-healing: re-encrypt all provider keys with current encryption key.
+///
+/// For each encrypted key, attempts decryption with the current key.
+/// If decryption succeeds, re-encrypts and updates in-place (idempotent).
+/// If decryption fails, logs a warning and marks the key inactive.
+pub async fn heal_provider_keys(db: &PgPool, enc_key: &[u8; 32]) -> usize {
+    let rows: Vec<(String, String)> = sqlx::query_as(
+        "SELECT id, key_value FROM provider_keys WHERE key_value LIKE 'enc:%'"
+    ).fetch_all(db).await.unwrap_or_default();
+
+    let mut healed = 0usize;
+    let mut failed = 0usize;
+
+    for (id, key_value) in &rows {
+        match crypto::decrypt_value(key_value, enc_key) {
+            Ok(plaintext) => {
+                // Re-encrypt with current key (idempotent if same key)
+                match crypto::encrypt_value(&plaintext, enc_key) {
+                    Ok(new_encrypted) => {
+                        if let Err(e) = sqlx::query(
+                            "UPDATE provider_keys SET key_value = $1 WHERE id = $2"
+                        ).bind(&new_encrypted).bind(id).execute(db).await {
+                            tracing::warn!("[heal] Failed to update key {}: {}", id, e);
+                        } else {
+                            healed += 1;
+                        }
+                    }
+                    Err(e) => {
+                        tracing::warn!("[heal] Failed to re-encrypt key {}: {}", id, e);
+                        failed += 1;
+                    }
+                }
+            }
+            Err(e) => {
+                tracing::warn!("[heal] Cannot decrypt key {}, marking inactive: {}", id, e);
+                let _ = sqlx::query(
+                    "UPDATE provider_keys SET is_active = FALSE WHERE id = $1"
+                ).bind(id).execute(db).await;
+                failed += 1;
+            }
+        }
+    }
+
+    if healed > 0 || failed > 0 {
+        tracing::info!("[heal] Provider keys: {} re-encrypted, {} failed", healed, failed);
+    }
+    healed
+}