A company would purchase a Hastelloy reactor primarily for its exceptional corrosion resistance and durability in harsh chemical processing environments. Here are the main reasons:
Hastelloy (a family of corrosion-resistant metal alloys primarily made of nickel, with varying amounts of molybdenum, iron, cobalt, and chromium) is highly resistant to Strong acids (e.g., hydrochloric, sulfuric, and nitric acids), Oxidizing and reducing agents, Chloride-induced pitting and stress corrosion cracking. This makes Hastelloy ideal for reactors used in chemical plants, pharmaceutical manufacturing, and other industries that deal with highly aggressive substances.
Hastelloy can withstand high temperatures, maintaining mechanical strength and chemical resistance, which is critical for High-pressure, high-temperature reactions and Exothermic or endothermic chemical processes. In industries like pharmaceuticals, aerospace, or nuclear, regulatory standards often require the use of materials that are proven to resist contamination, easily cleanable (as in cGMP requirements) and durable under repeated sterilization and harsh conditions. Hastelloy reactors are often used when the process involves highly reactive chemicals, catalyst systems that degrade common materials, multi-phase reactions involving corrosive gases, liquids, or solids. Industries That Commonly Use Hastelloy Reactors - Chemical processing, Pharmaceuticals, Petrochemicals, Aerospace and Waste treatment.
The primary differences between Hastelloy C-276 and other types of Hastelloy (such as C-22, C-2000, B-2, etc.) lie in their chemical composition, corrosion resistance, and specific application suitability.
Hastelloy C-276 is composition is high in nickel (~57%), molybdenum (~16%), chromium (~15.5%), with some iron and tungsten. C-276 has excellent resistance to strong oxidizers, chloride-containing environments, and wet chlorine gas, exceptional resistance to pitting, stress corrosion cracking, and crevice corrosion. Performs well in both oxidizing and reducing environments. Commonly used in Chemical processing, Pollution control, Pulp and paper industry and Waste treatment.
Hastelloy C-22 is an Improved version of C-276 with a higher chromium content than C-276 (around 22%). Better overall corrosion resistance than C-276, especially in mixed oxidizing/reducing environments. Superior resistance to wet chlorine, nitric acid, and ferric/ cupric chlorides. Works well in more aggressive chemical environments and Pharmaceutical and food-grade applications requiring cleaner passivation.
Hastelloy C-2000 is Designed for strong oxidizers and acids. Composition: Adds copper (~1.6%) to improve sulfuric acid resistance. Best resistance to sulfuric acid in the Hastelloy C-family. Has a Very broad chemical resistance range including sulfuric acid processes and advanced pharmaceutical and specialty chemical processing
Hastelloy B-2 / B-3 is from a different alloy family (B-series) so it is not as versatile as other Hastelloys. Compostion is very high molybdenum (~28–30%) with low chromium. Outstanding resistance to hydrochloric acid and other strongly reducing media but performs poorly in oxidizing environments (e.g., nitric acid, ferric salts). Uses include p pickling operations and chemical processing involving reducing agents.
Though more expensive upfront, a company would purchase a Hastelloy reactor to ensure reliable, safe, and long-term operation under conditions where cheaper materials would fail or require frequent replacement. It’s a strategic investment in process integrity and operational efficiency.