Sulfuric acid consumption, world

Sulfuric acid is the largest-volume chemical manufactured in the world and its consumption is often cited as an indicator of the general state of a nation s economy.28 About 41 million tons of sulfuric acid were produced in the United States in 2003, of which approximately 70 percent was used in fertilizer production. Its use extends to nearly every major chemical sector. This versatile acid is truly the workhorse of the chemical industry. 

More than 90% of world sulfur consumption is used in the production of sulfuric acid, much of which goes to the fertilizer industry. Smaller amounts of sulfur are used in the manufacture of gunpowder, matches, phosphate, insecticides, fungicides, medicines, wood, and paper products, and in vulcanizing rubber. Despite slight uncertainties in sulfur demand in the 1990s, its use is still predicted to grow. 

Sodium sulfate is an important heavy chemical in the chemical industry and is found in many mineral deposits. The world reserves are so large that with the present rate of consumption they are sufficient for several hundred years. In addition to extraction from natural sources, it is also produced in large quantities as a byproduct e.g. in the production of potassium salts, sodium chloride and borax and in chemical and metal producing processes. Dedicated manufacture e.g. from sodium chloride and sulfuric acid has become less important. 

Although the worlds demand for sulfur has steadily increased in this century, cycles of supply in excess of consumption followed by demand in excess of productive capacity began in the late 1950s. The periods of oversupply stimulated research for uses other than the traditional ones such as sulfuric acid and wood pulping. Groups were formed to conduct research into new areas as well as into areas once abandoned but warranting review because of technology advances. 

U.S. consumption of sulfur is about 12 million t/yr. For a relative comparison, a 1,000 MW IGCC power plant would produce about 70,000 t/yr sulfur (assuming a 3 weight percent (wt%) sulfur feed coal, 65% annual capacity factor, and 99% sulfur recovery). About 80% of this sulfur is converted to sulfuric acid in the production of phosphate fertilizer. Fertilizer demands for sulfur are expected to increase with time as world food demand increases. U.S. phosphate fertilizer production centers in Florida, which has large supplies of phosphate rock. 

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