Sulphuric Acid Market: Battery Manufacturing Demand, High-Purity Grades & Energy Storage Trends

According to IMARC Group's latest research publication, globa lsulphuric acid market size reached USD 15.8 Billion in 2024. Looking forward, IMARC Group expects the market to reachUSD 18.1 Billion by 2033, exhibiting a growth rate of 1.95%

How AI is Reshaping the Future of Sulphuric Acid Market

• Real-Time Process Optimization and Energy Management:

AI-powered systems adjust temperature, pressure, and catalyst loading in real-time during sulphuric acid production, minimizing SO₂ emissions below 50 ppm while reducing energy consumption through predictive control algorithms that optimize sulfur combustion and converter operations.

• Predictive Maintenance and Equipment Reliability:

Machine learning models monitor sensors across production facilities to detect corrosion in H₂SO₄ pipelines and predict equipment failures before breakdowns occur, reducing unplanned downtime and extending asset lifespan through data-driven maintenance scheduling.

• Quality Control and Purity Enhancement:

Automated quality assurance systems use online analyzers and digital batch traceability to maintain consistent purity levels for high-grade applications like semiconductor manufacturing and battery production, ensuring compliance with strict industry specifications and regulatory requirements.

• Supply Chain and Demand Forecasting:

AI analytics process historical production data, agricultural cycles, and industrial demand patterns to optimize inventory management and distribution logistics, helping manufacturers align supply with fertilizer production peaks and automotive battery requirements.

• Environmental Compliance and Emission Reduction:

Advanced monitoring systems continuously track SO₂ emissions and automatically adjust heat-recovery boilers and low-NOx burners to meet tightening environmental regulations, reducing carbon footprint while improving operational efficiency through intelligent waste heat utilization.

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Sulphuric Acid Industry Overview:

The sulphuric acid industry is experiencing transformation driven by evolving industrial requirements and sustainability initiatives. Global producers modernized facilities with heat-recovery systems that reduce SO₂ emissions while improving operational stability, as demonstrated by major upgrades completed in early 2025. Manufacturing capacity expanded significantly with new facilities launching across key markets, including a 90,000-ton capacity plant in India and strategic acquisitions like Ecovyst's purchase of Cornerstone Chemical's Louisiana assets to strengthen Gulf Coast supply networks. The sector is responding to dual pressures: meeting increased demand from fertilizer production, battery manufacturing, and metal processing while complying with stricter environmental standards. Companies are investing in automation, digital monitoring, and sustainable production methods to balance growth with regulatory compliance.

Sulphuric Acid Market Trends & Drivers:

• Fertilizer production remains the dominant driver, accounting for over 55% of global sulphuric acid consumption as agricultural demand intensifies with population growth and shrinking arable land. The compound is essential for manufacturing phosphate fertilizers like monoammonium phosphate (MAP) and diammonium phosphate (DAP), which farmers increasingly rely on to boost crop yields amid rapid urbanization. Rising food security concerns across developing economies are pushing governments to support agricultural productivity initiatives, directly benefiting sulphuric acid demand. Asia Pacific leads consumption, particularly China and India, where expanding agricultural activities and government subsidies for fertilizers create sustained market pull. Regional production capacities are scaling up to serve both domestic needs and export opportunities to neighboring markets.
• Electric vehicle adoption and battery manufacturing are creating new growth channels for high-purity sulphuric acid. Lead-acid batteries, which contain 28-32% sulphuric acid, power conventional vehicles and provide backup systems, while lithium-ion battery production requires ultra-pure sulphuric acid for processing cathode materials. EV battery demand surged over 25% reaching 950 GWh in 2024, with projections pointing toward 3 TWh by 2030 as electrification accelerates globally. The automotive sector's transformation is reshaping sulphuric acid specifications, with battery manufacturers demanding stricter purity standards and contamination-free supply chains. Companies are adding dedicated product lines and laboratory quality assurance capabilities to meet these requirements. Simultaneously, renewable energy storage systems are expanding battery applications beyond transportation, creating additional demand streams for battery-grade sulphuric acid.
• Metal processing and mining operations drive substantial sulphuric acid consumption through hydrometallurgical extraction of copper, nickel, zinc, and uranium from ores. The expansion of mining activities in emerging economies, coupled with infrastructure development projects, sustains industrial demand across Asia Pacific, Latin America, and the Middle East. Chemical manufacturing represents another major application segment, where sulphuric acid serves as a critical input for producing hydrochloric acid, nitric acid, and various sulfate salts. The petroleum refining industry utilizes significant volumes for fuel processing and quality enhancement. Additionally, water treatment facilities increasingly deploy sulphuric acid for pH adjustment and wastewater management as environmental regulations tighten globally. This diverse application portfolio provides market stability, though environmental compliance costs and raw material price volatility present ongoing challenges for producers.

Leading Companies Operating in the Global Sulphuric Acid Industry:

• Aarti Industries Ltd.
• Aurubis AG
• BASF SE
• Boliden AB
• Brenntag SE
• Chemtrade Logistics
• Lanxess AG
• Merck KGaA
• Nutrien Ltd.
• PhosAgro
• Solvay S.A.
• The Mosaic Company
• Valero Energy Corporation

Sulphuric Acid Market Report Segmentation:

By Raw Material Type:

• Elemental Sulfur
• Pyrite Ore
• Others

Elemental sulfur represents the largest segment due to its abundant availability, cost-effectiveness, and lower environmental impact compared to alternative raw materials.

By Form:

• Concentrated (98%)
• Tower/Glover Acid (77.67%)
• Chamber/Fertilizer Acid (62.8%)
• Battery Acid (33.5%)
• 66 Degree Baume Sulfuric Acid (93%)
• Dilute Sulfuric Acid (10%)

Chamber/fertilizer acid (62.8%) holds the largest market share, driven by extensive use in phosphate fertilizer manufacturing.

By Distribution Channel:

• Offline
• Online

Offline distribution channels dominate due to the bulk nature of sulphuric acid transactions and stringent safety requirements that favor direct, face-to-face procurement.

By End Use Industry:

• Fertilizer
• Chemical and Pharmaceutical
• Automotive
• Petroleum Refining
• Others

Fertilizer industry accounts for the largest share as sulphuric acid is essential for producing phosphoric acid and various phosphate fertilizers critical to global agriculture.

Regional Insights:

• North America (United States, Canada)
• Asia Pacific (China, Japan, India, South Korea, Australia, Indonesia, Others)
• Europe (Germany, France, United Kingdom, Italy, Spain, Russia, Others)
• Latin America (Brazil, Mexico, Others)
• Middle East and Africa

Asia Pacific dominates the market, driven by rapid industrialization, extensive agricultural activities, and growing infrastructure development across China, India, and Southeast Asian nations.

Recent News and Developments in Sulphuric Acid Market:

• March 2025: Ecovyst Inc. acquired Cornerstone Chemical Company's sulfuric acid production assets in Waggaman, Louisiana, expanding Ecoservices' capacity to serve both regeneration and virgin sulfuric acid customers while offering greater flexibility within the company's Gulf Coast plant network.
• July 2024: Aurubis AG successfully restarted its Hamburg copper smelter following a €95 million maintenance shutdown, which included overhauling the flash smelter and installing new heat exchangers in the contact acid plant. The restart eased tight sulphuric acid supply in the region after shortages caused by molten sulfur limitations.
• July 2024: OCP Group awarded Worley Chemetics the contract for three new sulfuric acid plants at the Mzinda Phosphate Hub in Morocco, covering proprietary technology and detailed engineering services to support expanded fertilizer production capacity.
• May 2025: Sumitomo Corporation formed a joint venture with NFC Public Company Limited to operate a sulfuric acid tank-terminal network in Thailand, establishing a regional logistics hub to improve supply chain efficiency across Southeast Asia.
• October 2024: Yashvardhan Chemical Industries announced plans to produce sulfuric acid (70-98%) with a capacity of 90,000 tons, addressing growing domestic demand in India's fertilizer and chemical manufacturing sectors.

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