Sulfuric Acid

SULFURIC ACID

[EIRI/EDPR/4396] J.C.: 2593XL

INTRODUCTION

Sulfuric acid/ Sulphuric acid is a mineral acid composed of the chemical elements sulfur(S), oxygen(O) and hydrogen(H), with the molecular formula of H2SO4. Produced through the conventional double contact double absorption process (DCDA) or the wet sulfuric acid process (WSA). Its appearance is colourless, odourless and viscous liquid that is miscible with water and soluble. It is known in antiquity as Oil of Vitriol or Hydrogen Sulphate. Apart from being hygroscopic and exothermic in nature, major property of sulfuric acid is its dehydrating nature.

As it readily absorbs water vapour from the air, it’s pure form does not exists. Sulfuric acid is an important commodity chemical.Because the acid can be used in production of various chemicals and fertilizers, in oil refining, in mine-ore processing,in chemical synthesis and in other processes, so a country’s sulphuric acid production can be a good indicator of its industrial strength.

MARKET SHARE & TRENDS :

Recent study done on the global sulphuric acid market size, it was estimated at USD 14.3 billion in 2021 and is further expanding to USD 29.7 billion by 2030 with a steady CAGR of 8.46% during the forecast period 2022 - 2030. The global consumption of sulphuric acid is attributable at 35 - 40% of the overall acids market in the world.In 2021, production of fertilizers on demand of the farmers was the most dominating application segment and thus, contributed over 50% of market revenues.Sulfuric Acid Market to exceed USD 25,623 million by 2032 amid its rising applications.

Key Market Drivers :

• Requirements in agriculture sector - Increased demands in the agricultural activities with adapting the sulfuric acid for increasing the productivity of the crops by mixing it with soil.Sulfuric acid contains few vital nutrients such as phosphorous(P), potassium(K), and nitrogen(N) which are those main components that aids the crops grow with improved quality and quantity. 

• Requirements in chemical industry - Wide utilization of sulfuric acid here is as a raw material used as a processor in manufacturing the new chemical synthesis or producing the drugs. Manufacturing of various different chemicals using new developments as per increased demands from the consumers has enhanced the market. Also, there is rise in demands for the nitric acid, sulphate salts, detergents, dyes, pigments, hydrochloric acid, explosives and other drugs in the pharmaceutical industries.

• Requirements in automobile industry- Enhance demand from this industry is due to increased utilization in making of  batteries which helps for storing the energy in it. With increasing number of global electric vehicles, this acid market is sure to grow in future. 

• Utilization in various other sectors- Utilization in different industries such as textile industry, metal industry and oil & petroleum refining industries. Sulfuric acid is majorly utilized as cleaning agent in metal industry, for removal of corrosion which fuels the market of sulfuric acid. Also, because this acid has less pollution characteristics than that of pyrite ores.So the raw material segment in 2021, the elemental sulphur captured a substantial portion of the market which is proven to make rapid progress in future course of time.

FUTURE FORECAST :

1. Lack of skill amongst the people regarding the utilization and handling of the sulfuric acid, may lead to decrease in the market growth. But the increased rules and regulations imposed regarding its handling as its hazardous to the body, can continuously increase the prices of the sulfuric acid. Which may hamper the acid market growth of sulfuric acid. 

2. Due to rapid industrialization and trending urbanisation, the negative effect of reducing the area of land that is suitable for food production, are leaving the farmers helpless by forcing them to use the fertilisers in order to boost crop yields in a limited area. This in turn will gear up the production of sulphuric acid market.

3. With increased concerns of environmental issues around, the government is taking all possible initiative to come up with a process to reuse waste water as drinking water. Or at least, wastewater treatment that frees scarce freshwater resources for other uses or preservation and to destroy the bacteria in water which may cause several disorders. Here, the sulfuric acid plays a major role in waste water treatment. Wastewater treatment includes prevention of odour of water, separation of solid particles with chemicals such as ferric chloride, polymers, and alums using sulfuric acid. This would clearly drive the market of this acid globally. 

4. It is seen that during the period from 2017- 2025, there will be an increase in the implementation of standards such as New Source Performance Standards (NSPS) to regulate the emissions of sulphur dioxide (SO2), sulfuric acid mist, and nitrogen oxides from H2SO4 production facilities. This will lead to an expansion of the market.

In 2021, the Asia Pacific was the key region in terms of market revenue, accounting for around 45% of the overall revenue. It is anticipated that an increase in the output of sulphur from China and Japan will drive an increase in this region, leading to rise in the price of the product. Even in the electrical and pharmaceutical industries, the use of this acid will cause the market to grow fastest. North America and Europe so far are expected to collectively hold around 37% of the overall market share.

COST ESTIMATION

Plant Capacity                                    20 MT/Day

Land & Building (6000 sq.mt.)  Rs. 6.32  Cr

Plant & Machinery                              Rs. 10.08 Cr

Working Capital for 0.5 Months      Rs. 35.52 Lac

Total Capital Investment                  Rs. 17.85 Cr

Rate of Return                                    12%

Break Even Point                               76%

CONTENTS

INTRODUCTION

USES/APPLICATIONS

APPLICATIONS

MARKET OVERVIEW

GLOBAL SULFURIC ACID MARKET DEFINITION

GLOBAL SULFURIC ACID MARKET OVERVIEW

GLOBAL SULFURIC ACID MARKET SEGMENTATION ANALYSIS

SULFURIC ACID MARKET, BY RAW MATERIAL TYPE

SULFURIC ACID MARKET, BY APPLICATION

SULFURIC ACID MARKET, BY GEOGRAPHY

KEY PLAYERS

PROPERTIES

HAZARDS

REFER HAZARD SUBSTANCE FACT SHEET (ENCLOSED)

WORKPLACE EXPOSURE LIMITS

HANDLING

CHEMICAL REACTIONS/FORMULATION

THE CHEMICAL REACTIONS ARE AS FOLLOWS:

THE PROPOSED PROCESS IS BASED ON CONTACT PROCESS

RAW MATERIALS

ELEMENTAL SULPHUR

SUPPLIERS OF RAW MATERIALS

SULPHUR POWDER

PETROLEUM REFINERIES OF INDIA

TESTING CHEMICALS

MANUFACTURING PROCESS STEPS

PROCESS FLOW

ENGINEERING DESIGN CONSIDERATIONS

ETP FACILITY

ETP FLOW DIAGRAM (TYPICAL)

SEWAGE AND WASTE WATER EFFLUENT

STP FLOW DIAGRAM (TYPICAL)

WASTE GENERATION & MANAGEMENT/GREEN BELT

GREEN BELT

WATER (ESTIMATED)

WASTE (ESTIMATED)

FLUE GAS (ESTIMATED)

PLANT/MACHINERY (BROADLY)

PLANT AND EQUIPMENT

TREATMENT OF BURNER GAS

PREHEATERS AND COOLERS

CONVERTER

MATERIALS OF CONSTRUCTION

SUPPLIERS OF PLANT & MACHINERIES/TURNKEY

COMPLETE PLANT SUPPLIERS ON TURNKEY BASIS

PLANT AND MACHINERY

SCRUBBER

HEAT EXCHANGER

COOLING TOWER

STORAGE VESSEL FOR OLEUM AND SULPHURIC ACID

MATERIAL HANDLING EQUIPMENTS

INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS

LABORATORY EQUIPMENTS

POLLUTION CONTROL EQUIPMENTS

BOILERS

AIR COMPRESSORS

PROCESS EQUIPMENTS

STORAGE TANKS

D.G. SETS

POWER TRANSFORMERS

ETP PLANTS

PLATEFORM WEIGHING MACHINE

ELECTRICAL MEASURING INSTRUMENTS

SUBMERSIBLE WATER PUMP

UTILITIES PER MONTH (ESTIMATED)

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

FLOOD AND FIRE CONTROL:

HEALTH SAFETY AND ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HSE REQUIREMENT

SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING OF RAW MATERIAL & PRODUCT)

POTENTIAL RISKS

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

PRELIMINARY LAYOUT

CONCLUSIONS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)