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Hastelloy wire mesh
Hastelloy wire mesh is a functional filtration material made from nickel-based alloy wire through plain weave, twill weave, Dutch weave and other weaving processes. In addition, this type of woven mesh can also be used as a base layer and combined with more other layers through sintering to produce multi-layer sintered mesh.
It can meet the demands of harsh working conditions such as high pressure and high-precision filtration .
The Difference Between Hastelloy and Ordinary Stainless Steel
To understand the core value of Hastelloy wire mesh, it is essential to clarify that it is not in the same league as common stainless steels such as 304 and 316L. Instead, it is in a “dimensionally superior” position.
316L stainless steel is already considered a high-quality corrosion-resistant material in conventional industrial settings, but in comparison to Hastelloy, the performance gap is all-encompassing.
Take Hastelloy C276, the most widely used type, as an example. As a nickel-based alloy (with about 57% nickel), it contains a high proportion of molybdenum (16%), chromium (15%), and tungsten, among other alloying elements. It exhibits excellent resistance to both reducing and oxidizing environments. It remains stable in strong reducing acids like hydrochloric and dilute sulfuric acid, as well as in oxidizing media such as wet chlorine gas and hypochlorite. The high molybdenum content makes it almost immune to pitting in seawater and high-chloride environments. Moreover, it maintains good strength and oxidation resistance within the temperature range of 100-800°C, with an outstanding retention of strength at high temperatures, making it suitable for various high-pressure and high-temperature applications.
However, its cost is high, approximately eight times that of 316L stainless steel.
In contrast, 316L stainless steel, as an iron-based alloy (with iron as the base), contains only 16%-18% chromium, 10%-14% nickel, and 2%-3% molybdenum. It is an economical choice for general corrosive environments. It is suitable for medium-concentration nitric acid, organic acids, fresh water, or low-chloride environments, but it is not resistant to chloride ion corrosion and is prone to pitting and stress corrosion cracking in chloride-containing media. Its long-term service temperature usually does not exceed 400°C. It has stable mechanical properties in medium and low-temperature environments but has a shortcoming of poor high-temperature creep resistance.
In brief, If the process environment is “normal temperature, chlorine-free, and non-strong acid”, 316L stainless steel is sufficient; but if any of the extreme conditions such as high temperature, high pressure, strong acid (especially mixed acid), or high chloride ions is involved, Hastelloy alloy is indispensable.
Hastelloy Alloy Mesh
Similar to ordinary metal wire mesh, Hastelloy alloy wires can also be woven into various structural mesh products through multiple weaving methods, such as square mesh, Dutch mesh, contrast mesh, etc. It should be noted that the material properties of Hastelloy alloy wires make it difficult to be drawn to extremely fine specifications like stainless steel wires. In regular batch production, 200 mesh is the technological critical point for Hastelloy alloy woven mesh. After exceeding 200 mesh, the processing difficulty will sharply increase, and the yield will significantly decrease. Therefore, it is extremely rare in the market. The stable production range of wire diameters is usually 0.1mm – 12mm. If high filtration accuracy is required (equivalent to above 200 mesh), the Dutch weaves can be selected: through plain weave Dutch weaving or diagonal weave Dutch weaving, using thicker wire diameters to achieve micron-level absolute filtration accuracy.
Applications of Hastelloy Alloy Wire Mesh
- Petroleum Industry: Used in core components such as reactor catalyst recovery, acid washing tower demisting devices, distillation tower internals filtration, and heat exchanger filter elements.
- Sulfur Dioxide Removal from Flue Gas: Applied in absorber tower demisting devices and slurry filtration devices. The flue gas contains a large amount of sulfur dioxide and chlorides, forming a highly corrosive mixed environment of sulfuric acid/chloride ions. The acid resistance and reduction resistance of Hastelloy C276 make it the standard material selection in this industry.
- Nuclear Industry: Mainly used in nuclear waste treatment filters and borate recovery systems for scenarios with strong corrosion and high safety requirements.
- Ocean Engineering: Suitable for seawater desalination pre-treatment filter nets, offshore platform equipment filters, and seawater lift pump filters in high-salt corrosion environments.
- Biopharmaceutical Industry: Used for high-purity raw material drug filtration and sterile filtration of fermentation tanks, with strict requirements for material corrosion resistance and cleanliness.
- Acetic Acid/Acetone Production: As the core material for reactor filters and product refining filters, able to withstand strong corrosive media during the production process.
- New Energy Field: Applied in electrolytic water hydrogen production electrode net support layers and acid leaching filtration systems for emerging high-end scenarios.
