A Hastelloy screen is a woven wire screen cloth made from Hastelloy nickel-based superalloy wire, used in vibratory screeners for applications involving highly aggressive chemicals, strong acids, and corrosive environments that would rapidly destroy stainless steel screen cloth. Hastelloy is a family of nickel-molybdenum and nickel-chromium-molybdenum superalloys originally developed by Haynes International. The two grades most commonly used for screen cloth are Hastelloy C-276 (57% Ni, 16% Cr, 16% Mo) and Hastelloy C-22 (56% Ni, 22% Cr, 13% Mo), both of which offer corrosion resistance far beyond what any stainless steel grade can provide.
Hastelloy screens are specified when the chemical environment is too aggressive for 316 stainless steel. This includes processing with hydrochloric acid, sulfuric acid at elevated concentrations and temperatures, mixed acids, chlorine gas, wet chlorine, and other highly oxidizing or reducing environments found in chemical manufacturing, pulp and paper, waste treatment, and specialty pharmaceutical operations. While Hastelloy screen cloth costs 8-15 times more than 304 SS, its extreme corrosion resistance can make it the most economical choice when measured against total screen replacement cost and downtime in corrosive applications.
Hastelloy Screen Properties
| Property | Hastelloy C-276 | 316 SS (Comparison) |
|---|---|---|
| Nickel Content | 57% | 10–14% |
| Molybdenum Content | 16% | 2–3% |
| Chromium Content | 16% | 16–18% |
| Pitting Resistance (PREN) | >70 | 23–28 |
| HCl Resistance | Excellent (all concentrations at room temp) | Poor |
| H₂SO₄ Resistance | Excellent (to 60% at 80°C) | Poor above 5% |
| Tensile Strength | 690–790 MPa | 515–620 MPa |
| Max Service Temperature | 1,093°C (2,000°F) | 870°C (1,600°F) |
| Cost Index vs. 304 SS | 8–15x | 1.2–1.3x |
Why This Matters in Vibratory Screening
Hastelloy screen represents the highest tier of chemical corrosion resistance available in woven wire screen cloth. It is a premium solution reserved for environments where no stainless steel grade can survive.
- Extreme acid resistance — Hastelloy C-276 resists hydrochloric acid at all concentrations at room temperature and sulfuric acid to 60% concentration at elevated temperatures. No stainless steel, including 316 SS, can tolerate these environments without rapid corrosion.
- Mixed-acid environments — Chemical plants often produce mixed-acid conditions (e.g., HCl + H₂SO₄, or oxidizing + reducing conditions cycling). Hastelloy's balanced nickel-chromium-molybdenum composition resists both oxidizing and reducing acids, whereas most alloys resist only one type.
- Total cost of ownership — Despite costing 8-15 times more per screen, Hastelloy screens often deliver the lowest cost per ton of screened material in aggressive chemical environments. A single Hastelloy screen lasting 12 months costs less than replacing a 316 SS screen every 2-4 weeks.
- Product purity — In pharmaceutical and specialty chemical operations, corroding screen wire contaminates the product with metallic ions. Hastelloy's resistance to corrosion ensures product purity in aggressive chemical separations.
Related Glossary Terms
- Inconel Screen — Nickel superalloy for high-temperature screening
- Monel Screen — Nickel-copper alloy for seawater and acid resistance
- 316 Stainless Steel — The standard upgrade from 304 SS for corrosive environments
- Corrosion Resistance — A material's ability to resist chemical degradation
- Passivation — Surface treatment that enhances corrosion resistance
Hastelloy Screen FAQs
When is Hastelloy screen required instead of 316 stainless steel?
Hastelloy screen is required when the screened material or operating environment contains aggressive chemicals that attack even 316 stainless steel. Typical scenarios include screening in the presence of hydrochloric acid, sulfuric acid above 5% concentration, mixed acids, chlorine gas, wet chlorine, hypochlorite solutions, and highly oxidizing or reducing environments. If 316 SS screens are showing rapid pitting, crevice corrosion, or general corrosion, Hastelloy is typically the next step up.
How much does Hastelloy screen cost compared to stainless steel?
Hastelloy screen cloth costs approximately 8-15 times more than equivalent 304 stainless steel screen cloth, depending on the specific Hastelloy grade, mesh size, and wire diameter. Despite the high initial cost, Hastelloy screens can be the most economical choice in severely corrosive environments because they may last 10-20 times longer than stainless steel, dramatically reducing total replacement costs, downtime, and product contamination risk.
Order Hastelloy Replacement Screens
ScreenerKing manufactures Hastelloy C-276 and C-22 replacement screens for the most demanding chemical screening applications — compatible with Sweco, Kason, Midwestern Industries, Russell Finex, and other OEM vibratory separators. Custom fabrication with extended lead times.
