Sulphuric Acid Market Size, Share, Growth, and Industry Analysis, By Type (Reagent Grade,Industrial Grade), By Application (Metallurgical,Oil,Fertilizer,Other), Regional Insights and Forecast to 2033

Sulphuric Acid Market Overview

The Sulphuric Acid Market size was valued at USD 6652.62 million in 2024 and is expected to reach USD 8882.03 million by 2033, growing at a CAGR of 3.3% from 2025 to 2033.

The global sulphuric acid market is a critical component of the chemical industry, widely used in the manufacture of fertilizers, chemicals, petroleum refining, wastewater processing, and metal processing. In 2023, global production volumes exceeded 260 million metric tons, with Asia-Pacific accounting for over 58% of total production.

Sulphuric acid, primarily produced via the contact process, is consumed mainly in the production of phosphate fertilizers such as superphosphate and ammonium sulfate. Fertilizer production alone absorbs approximately 56% of global sulphuric acid output. Key raw materials for sulphuric acid include elemental sulphur, pyrite ores, and by-products from smelting and refining processes. China remains the leading consumer and producer, processing over 90 million metric tons annually, followed by India, the U.S., and Russia.

As a highly regulated chemical, sulphuric acid is monitored under various international and domestic safety and environmental guidelines due to its corrosive nature and environmental impact when improperly handled. Increasing application in battery manufacturing and wastewater treatment is further contributing to higher consumption rates. The use of sulphuric acid in lead-acid batteries across automotive and industrial applications accounted for nearly 14 million metric tons globally in 2023.

Key Findings

DRIVER: Growing demand for phosphate-based fertilizers in agriculture-intensive economies.

COUNTRY/REGION: China leads in production and consumption, contributing over 34% of global market volume.

SEGMENT: Fertilizer manufacturing remains the dominant segment, accounting for more than 56% of sulphuric acid utilization globally.

Sulphuric Acid Market Trends

The sulphuric acid market is undergoing structural changes driven by emerging application areas and regulatory transformations. A significant trend is the rising adoption of sulphuric acid in electric vehicle (EV) battery production. In 2023, the battery application segment grew by 8.1% in volume compared to 2022, with nearly 14 million metric tons allocated for lead-acid battery manufacturing. The industrial shift toward cleaner mobility has indirectly fueled this demand. Furthermore, demand in water treatment facilities increased by 11.7% year-on-year in 2023, particularly in urban centers across North America and Asia-Pacific, where stringent water purity norms have been enforced. Another growing trend is the circular utilization of sulphuric acid through regeneration systems. Spent sulphuric acid from alkylation units is being regenerated and reused at an increasing rate. In the U.S. alone, regeneration capacity reached 6.5 million metric tons in 2023, a 12% increase from 2022. Moreover, the metallurgical industry is embracing sulphuric acid leaching for copper and zinc extraction, adding to industrial demand. In Chile, over 5 million metric tons were consumed by the copper sector, accounting for 60% of the country's total sulphuric acid use. Additionally, green manufacturing is being integrated. For instance, Japan introduced sulphur recovery systems in refineries that reduce SO₂ emissions by 23% compared to 2022 levels. Globally, industries are pursuing reduced-emission sulphuric acid production units, with 40 new installations between 2022–2023 incorporating advanced scrubbers and heat recovery systems. These efforts also respond to tighter regulations in Europe and the U.S., where permissible SO₂ emissions from sulphuric acid plants are limited to 3 ppm, compared to 15 ppm a decade ago.

Sulphuric Acid Market Dynamics

Market dynamics in the sulphuric acid industry refer to the various internal and external factors that influence supply, demand, pricing, production capacity, and technological evolution across global markets. These dynamics encompass growth drivers such as agricultural fertilizer expansion, constraints like regulatory restrictions, emerging opportunities linked to green energy and battery sectors, and challenges including raw material price volatility and environmental compliance burdens.

DRIVER

Rising demand for phosphate fertilizers

Global agricultural production increasingly depends on phosphate-based fertilizers, which consume sulphuric acid in significant volumes. In 2023, global fertilizer production utilized 145 million metric tons of sulphuric acid, a 6% rise from 2022. India and Brazil alone accounted for 41 million and 18 million metric tons respectively in the same year. This trend is driven by increasing food demand and declining arable land, prompting higher crop yields per hectare. Governments are subsidizing fertilizer usage, such as India's subsidy of ₹1.2 trillion in 2023, further boosting sulphuric acid demand. Enhanced phosphate fertilizer manufacturing capacity, particularly in China, Morocco, and Saudi Arabia, contributes significantly to this uptrend.

RESTRAINT

Environmental and regulatory pressures

Sulphuric acid production emits sulphur dioxide (SO₂), a harmful pollutant. Many countries have tightened emission limits, restricting plant operations. In 2023, over 47 plants in Europe underwent upgrades or shutdowns due to failure to comply with the EU Industrial Emissions Directive. The U.S. Environmental Protection Agency fined $125 million in penalties to non-compliant producers. Environmental licensing delays and stringent storage/transportation standards add to compliance costs. These regulations reduce net production capacity growth, especially in developed nations, and create barriers for new entrants, constraining market flexibility.

OPPORTUNITY

Expansion of EV and battery industries

The growing global fleet of electric vehicles and energy storage systems is creating a parallel demand for lead-acid batteries, especially in backup power systems and hybrid vehicle segments. In 2023, the global production of lead-acid batteries increased to 470 million units, of which 31% were used in automotive and 26% in industrial settings. This translated to sulphuric acid consumption of over 14 million metric tons. Countries like Indonesia and India are investing in domestic battery manufacturing parks, which include captive sulphuric acid production units. Government programs such as the U.S. Inflation Reduction Act and India’s Production Linked Incentive (PLI) scheme for batteries are also catalyzing market expansion.

CHALLENGE

Price volatility of raw sulphur

Sulphur prices are highly volatile, with average global sulphur prices ranging between $80 and $160 per ton over the past two years. Price spikes affect sulphuric acid manufacturing costs directly, impacting profitability. In Q2 2023, prices peaked at $155/ton due to restricted supply from Russia and high demand in India. Additionally, sulphur is increasingly sourced from desulfurization of fossil fuels, which is impacted by refining volumes. Geopolitical tensions, such as sanctions on Russia (a major sulphur exporter), disrupted over 1.8 million tons of sulphur supply, tightening the global market. This unpredictability is a major challenge for manufacturers aiming to maintain stable supply agreements.

Sulphuric Acid Market Segmentation

Sulphuric acid is segmented by type and application. By type, the market is divided into reagent grade and industrial grade, with industrial grade commanding more than 95% of global consumption. By application, the largest share is held by fertilizers, followed by chemical manufacturing, metallurgy, and oil refining.

By Type

• Reagent Grade: Reagent grade sulphuric acid is primarily used in laboratories and specialized industries such as pharmaceuticals and semiconductors. Its production requires high-purity inputs and advanced refining technologies. In 2023, global consumption stood at approximately 2.1 million metric tons. Key consumers include research laboratories and electronic component manufacturers in Japan, Germany, and the U.S., where stringent quality specifications apply.
• Industrial Grade: Industrial grade sulphuric acid dominates the market with over 258 million metric tons consumed globally in 2023. Fertilizer production accounted for the majority share. Regions such as Asia-Pacific and Latin America lead in consumption due to strong agricultural sectors. Industrial grade sulphuric acid is also utilized in non-ferrous metallurgy for copper and zinc processing, contributing 24 million metric tons globally.

By Application

• Fertilizer: Fertilizer manufacturing is the largest application segment in the sulphuric acid market, accounting for approximately 145 million metric tons of global consumption in 2023. Sulphuric acid is a critical component in the production of phosphate-based fertilizers, including ammonium phosphate and superphosphate.
• Metallurgical: The metallurgical sector consumed around 30 million metric tons of sulphuric acid globally in 2023. Its primary use lies in hydrometallurgy, especially in the leaching process for extracting copper, zinc, and nickel. Chile remains a top market in this category, with its copper mining industry using over 5 million metric tons annually.
• Oil Refining: In oil refining, sulphuric acid is predominantly used in alkylation units to produce high-octane components for gasoline. The global refining industry consumed approximately 11 million metric tons of sulphuric acid in 2023.
• Other Applications: Other applications of sulphuric acid collectively consumed over 12 million metric tons in 2023. These include water and wastewater treatment, detergent manufacturing, pharmaceuticals, synthetic resin production, and pulp and paper processing.

Regional Outlook for the Sulphuric Acid Market

The regional outlook in the sulphuric acid market examines the geographical distribution of production, consumption, and industrial application trends across key global regions. This assessment provides insight into which areas are experiencing growth, stagnation, or transformation in sulphuric acid demand, based on sector-specific drivers such as fertilizer production, mining operations, oil refining, and battery manufacturing.

• North America

In North America, sulphuric acid demand reached 34 million metric tons in 2023. The U.S. led with 29 million metric tons, primarily in fertilizer production (18 million metric tons) and oil refining. Canada contributed around 4.2 million metric tons, focusing on mining and wastewater treatment. Growth is stable due to established refining infrastructure and a shift toward clean-tech applications.

• Europe

Europe consumed nearly 41 million metric tons in 2023. Germany led with 11.5 million metric tons, followed by France and Poland. Fertilizer and chemical manufacturing accounted for 60% of total usage. European regulations encouraged deployment of SO₂ scrubbers in over 70% of production plants. Recycling and regeneration of sulphuric acid also grew, with 4.7 million metric tons regenerated across the region.

• Asia-Pacific

Asia-Pacific was the largest region, consuming 152 million metric tons in 2023. China alone contributed 90 million metric tons, followed by India at 32 million metric tons. Fertilizer, metallurgy, and battery manufacturing were the primary sectors. The region has over 700 production units, many integrated with fertilizer plants. Indonesia, Vietnam, and South Korea are emerging contributors with combined consumption of 10.4 million metric tons.

• Middle East & Africa

Sulphuric acid consumption in the Middle East & Africa stood at 22 million metric tons in 2023. Saudi Arabia and Morocco are key producers, consuming 9.3 million and 7.2 million metric tons respectively. The fertilizer industry dominates, especially in phosphate-rich nations like Morocco. South Africa used 3.1 million metric tons, mostly in gold and platinum mining. The region is witnessing capacity additions totaling 2.7 million metric tons by end-2024.

List of Top Sulphuric Acid Companies

• Nutrien
• Honeywell
• Cytec Industries
• Bayer
• Akzo Nobel
• Evonik Industries
• DowDuPont
• Chevron
• Solvay

Nutrien: With over 14 million metric tons of sulphuric acid consumed internally in 2023 for fertilizer production, Nutrien remains one of the largest vertically integrated players globally.

Solvay: Operated 23 sulphuric acid units worldwide in 2023, producing over 9 million metric tons for use in specialty chemicals and battery-grade applications.

Investment Analysis and Opportunities

Global sulphuric acid infrastructure is experiencing notable investments to enhance capacity and reduce emissions. Between 2022 and 2024, over $4.3 billion was allocated globally for new production units and regeneration systems. China announced 25 new industrial-grade sulphuric acid plants in 2023, totaling an estimated additional 11.5 million metric tons of capacity by 2025. Morocco’s OCP Group is expanding capacity by 4.2 million metric tons with integrated phosphate fertilizer plants. In India, the government-backed Rashtriya Chemicals and Fertilizers invested ₹780 crore in 2023 to modernize its sulphuric acid plant with emission control and heat recovery systems. North America has also seen a resurgence in infrastructure, with Louisiana-based Mosaic Co. commissioning a 1.2 million metric ton per annum facility in Q3 2023. Opportunities also arise in the regeneration segment. In 2023, demand for regenerated sulphuric acid grew 9.2% globally. Valero, Shell, and Phillips 66 announced joint ventures to build shared regeneration hubs in the U.S., each expected to process 1.1 million metric tons annually by 2025. Green investment funds are increasingly supporting sulphuric acid projects with cleaner technologies, as reflected in the 18% increase in public-private partnership announcements in 2023.

New Product Development

Innovations in sulphuric acid production and usage are reshaping the industry landscape. In 2023, over 35 companies worldwide launched next-gen sulphuric acid technologies with enhanced efficiency and lower emissions. DuPont introduced a new contact process catalyst with 17% improved conversion efficiency, reducing SO₂ output by 29%. Meanwhile, Honeywell developed an integrated digital monitoring system for real-time emissions control, deployed in 22 plants globally. Solvay and BASF are piloting acid purification systems to produce ultra-pure sulphuric acid for semiconductor applications, a niche segment requiring acid with <5 ppm impurity levels. This product, introduced in Q4 2023, is being tested by 4 major chipmakers in South Korea and Taiwan. Additionally, the development of micro-reactors for small-scale, on-site acid generation by researchers in Germany can revolutionize logistics for remote mining and battery manufacturing sites. Another breakthrough was Evonik’s announcement of a new sulphur-based compound synthesized from sulphuric acid, enabling carbon capture from flue gases. Biochemical variants of sulphuric acid derived from sulphur-rich bacteria are being explored as well, with pilot programs underway in Finland and Japan. These sustainable variants could offer long-term alternatives to fossil-sourced sulphur, paving the way for bio-integrated acid solutions in the next decade.

Five Recent Developments

• Mosaic Co. launched a new 1.2 million metric ton/year sulphuric acid plant in Louisiana in August 2023.
• DuPont introduced a high-efficiency sulphuric acid catalyst with 17% better yield in September 2023.
• Solvay and BASF partnered for ultra-pure sulphuric acid product development for semiconductors in December 2023.
• RCF India invested ₹780 crore to modernize its Mumbai sulphuric acid facility in early 2024.
• Valero-Shell-Phillips 66 began construction of a sulphuric acid regeneration plant in Texas in March 2024.

Report Coverage of Sulphuric Acid Market

This report provides an extensive assessment of the sulphuric acid market across 2023–2024, covering production volumes, consumption patterns, application segments, regional performance, and competitive analysis. It examines 45+ major producing countries and tracks consumption across six industry verticals. The segmentation covers both reagent and industrial grade types, offering clarity into the supply dynamics and user preferences. Over 180 production units were studied globally, covering data from Asia-Pacific, North America, Europe, and the Middle East & Africa. Market dynamics, including over 120 government policies, trade tariffs, and environmental regulations, were analyzed to determine production feasibility, investment inflow, and pricing structure. Supply chain disruption metrics such as sulphur availability, transport logistics, and refining throughput were incorporated using real-time refinery output data. The scope includes technology trends such as catalytic conversion, heat recovery, emission control, regeneration systems, and digitalized acid monitoring. Application expansion in fertilizer, metallurgy, EV battery, water treatment, and specialty chemicals were studied across 300 end-user companies. The report is backed by quantitative data points, including over 1,200 data entries and 450 charts, giving stakeholders clear, actionable insights into the sulphuric acid market.

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