I. Material Nature: The Corrosion Resistance Legend of Nickel-Based Alloys
Hastelloy is a high-performance, corrosion-resistant alloy with a nickel matrix and added elements such as molybdenum, chromium, tungsten, and iron. It was pioneered by Haynes International in the United States in the 1920s. Its core advantage stems from its ingenious compositional design: a high nickel content (50-60%) creates a corrosion-resistant framework, chromium (15-23%) forms a dense passive film in oxidizing environments, molybdenum (15-16%) significantly enhances pitting resistance, and tungsten (3-4.5%) further enhances corrosion resistance in complex media. This multi-element synergy enables Hastelloy to demonstrate unparalleled performance in extreme operating conditions such as strong acids and bases, high temperatures, and high pressures.
Based on application scenarios, Hastelloy alloys can be divided into three series:
B Series (such as B-2 and B-3): Primarily resistant to reducing acids, Hastelloy alloys offer exceptional performance in media such as hydrochloric acid and sulfuric acid. For example, the annual corrosion rate of B-2 alloy in boiling hydrochloric acid is less than 0.002mm, one thousandth that of 316L stainless steel.

C series (such as C-276 and C-22): Offers the strongest overall corrosion resistance, resisting both oxidizing and reducing corrosion. C-276 boasts a service life exceeding 36 months in a wet chlorine environment, far exceeding the 14 months of titanium. C-22, with its optimized welding properties, has become a mainstream choice for chemical equipment.

G series (such as G-30 and G-35): Their high chromium content makes them excellent in phosphoric acid and strongly oxidizing mixed acids, making them commonly used in fertilizer production. II. Technological Breakthrough: Innovation in the Entire Process from Smelting to Processing
Modern Hastelloy alloys are commonly produced using a dual process combining vacuum induction melting (VIM) and electroslag remelting (ESR), even incorporating vacuum consumable remelting (VAR). This reduces impurity levels such as sulfur and phosphorus to below 10 ppm and oxygen to below 15 ppm, significantly improving material purity and uniformity. For example, Jiangsu Huibei Special Alloys successfully produced C-276 cold-rolled coil with a tensile strength exceeding 690 MPa using a 6-ton ultra-large ingot, achieving internationally advanced performance in all aspects.

Welding Technology Optimization: Early Hastelloy alloys were prone to corrosion in the heat-affected zone (HAZ) due to their high carbon and silicon content. Refining techniques to reduce these carbon and silicon contents, coupled with the development of new welding consumables (such as C-22HS welding wire), have significantly improved welding performance. For example, by adjusting the composition of C-22 alloy, corrosion resistance and workability issues in the weld zone have been completely resolved, making it the most cost-effective C-series material. Emerging processing technologies have made progress in the development of Hastelloy alloy powders specifically for 3D printing. Gangyan Gaona's laser additive manufacturing powder has achieved aviation certification, increasing its added value per ton by 2.3 times. Nano-modification technologies (such as the addition of 2% nano-alumina) have further expanded its application, improving the oxidation resistance of B-4 alloy by 40% in a 1000°C hydrogen environment, making it suitable for fuel cell reactors.

III. Application Landscape: Strategic Support from Deep Sea to Space

Energy Sector

Petrochemical: C-276 alloy is the preferred material for hydrocracking units and reforming reactors. After adopting B-2 alloy reactors, a refinery has extended its equipment life from 18 months to 60 months, saving 3.2 million yuan in annual maintenance costs.

Nuclear Power: C-276 is used in nuclear reactor cooling systems, offering temperature resistance up to 800°C and excellent radiation resistance. The advancement of nuclear power projects in Zhangzhou, Fujian, and Taipingling, Guangdong, has driven an average annual growth of 12% in related demand. New Energy: Demand for B-3 alloy in hydrogen storage and transportation equipment is growing by over 15%, thanks to its resistance to high-pressure hydrogen (>70 MPa) and hydrogen embrittlement corrosion. Lithium battery electrolyte production equipment relies on the ultra-high purity of C-22 alloy.
Environmental Protection and Chemical Industry
Flue Gas Desulfurization and Denitrification: C-22 alloy withstands acidic environments with Cl⁻ concentrations exceeding 50,000 ppm in wet desulfurization towers, extending its service life by more than five times that of stainless steel.
Hazardous Waste Treatment: Supercritical Water Oxidation equipment uses C-2000 alloy, capable of treating highly toxic organic matter at 600°C and 25 MPa, with a corrosion rate of less than 0.02 mm/year.
High-End Manufacturing
Aerospace: C-276 is used in C919 engine nacelle fasteners, while X alloy withstands temperatures of 1200°C in gas turbine combustors. Domestic substitution rates are gradually increasing. Semiconductors: G-35 alloy transports high-purity gases (such as SiH₄ and NF₃), ensuring metal ion-free wafer manufacturing.

IV. Market Landscape: Domestic Substitution and Global Competition
Market Size and Growth: In 2024, the Chinese Hastelloy alloy market reached 4.87 billion yuan, a year-on-year increase of 6.3%. It is expected to increase to 5.18 billion yuan in 2025 and exceed 14.5 billion yuan in 2030, with a compound annual growth rate of 9.7%. Demand growth is primarily driven by new energy, nuclear power, and semiconductors, with hydrogen storage and transportation and small-scale nuclear reactors (SMRs) contributing significant incremental growth.

Competitive Landscape
International Giants: Haynes International maintains a dominant position in the high-end market, with its C-2000 and C-22HS grades holding over 70% market share in key nuclear island components.

Domestic Breakthroughs: Companies such as Baoti Group, Fushun Special Steel, and Jiangsu Longda are accelerating domestic substitution efforts. For example, Baoti Group's C-276 plate has been certified by Sinopec, with sales revenue reaching 630 million yuan in 2024. Jiangsu Longda's C-22 alloy holds an 18.4% market share in the desulfurization and denitrification markets, ranking second in China.
Challenges in the Industrial Chain
Raw Material Dependence: Import dependence on key elements such as nickel and molybdenum is high (nickel self-sufficiency rate is 38.6% in 2024). Risks need to be mitigated through the establishment of national reserves and technological breakthroughs (such as high-purity chromium preparation processes).
Technical Barriers: Breakthroughs are still needed in high-end products such as ultra-high-temperature alloys (temperature resistance ≥1200°C) and precision castings. Import dependence is expected to drop to 43% by 2025, but materials for nuclear power main pumps will still rely partially on imports.
V. Future Trends: Green and Intelligent Development Go Hand in Hand
Material Performance Upgrade
Ultra-High-Temperature Alloys: Develop Hastelloy alloys with a temperature resistance of over 1200°C, with the goal of achieving a 40% penetration rate in the aviation engine sector by 2030. Extreme Environment Resistance: Developing a modified C-276 alloy resistant to supercritical CO₂ corrosion, suitable for carbon capture and storage (CCUS) projects.
Process Innovation
Smart Manufacturing: Digital twin technology optimizes the melting and casting process, increasing yield to 92%. Companies in Jiangsu and Zhejiang have achieved full digital production line coverage, reducing unit energy consumption by 23%.
Circular Economy: Increase the waste recycling rate from 38% in 2025 to 55% in 2030, reducing carbon emissions per ton of product by 30%.
Policy and Market Drivers
Domestic Substitution Policy: The Ministry of Industry and Information Technology has designated high-purity nickel and molybdenum as key basic materials and supports the establishment of a reserve mechanism. It is expected that by 2025, the market share of domestic companies in the nuclear power and semiconductor sectors will increase to over 65%. Global Layout: China's Hastelloy alloy exports are expected to increase from 12,000 tons in 2025 to 28,000 tons in 2030, with a focus on developing the energy infrastructure market along the Belt and Road Initiative. However, this also requires addressing the quality certification requirements of the EU Carbon Border Adjustment Mechanism (CBAM).
VI. Typical Case Study: From Laboratory to Industrial Site
A chlor-alkali company: Using G-30 alloy wet chlorine treatment equipment, it operated continuously for 36 months at 95°C and a 98% Cl₂ concentration. This extended the lifespan of titanium equipment by 1.6 times, saving 1.8 million yuan in annual replacement costs.
A pharmaceutical intermediate project: Using B-3 alloy reactors, it operated at 120°C and 50% sulfuric acid for 9 years without failure, extending the replacement cycle by 6 years compared to 316L stainless steel equipment, generating direct economic benefits of 42 million yuan. At an LNG receiving terminal, domestically produced C-22HS pipes have passed international certification and are used in -196°C cryogenic heat exchangers. Replacing imported products reduces costs by 30%, filling a domestic technological gap.

Hastelloy alloy, with its "steel stomach"-like corrosion resistance, continues to drive technological breakthroughs in the chemical, energy, and environmental protection sectors. With the acceleration of domestic substitution and process innovation, this strategic material will play an even more critical role in high-end manufacturing and green transformation, becoming a core cornerstone supporting China's industrial upgrading.