Industrial acids such as sulphuric, hydrochloric and nitric acid are among the highest-volume raw materials in chemical manufacturing, used in fertiliser production, metal pickling and surface treatment, battery electrolyte, and as reagents in a wide range of chemical synthesis routes. Their corrosive nature makes handling and process design a central consideration for any manufacturer working with them.
Key points
- Sulphuric acid is the highest-volume industrial acid, with the majority of global output going to phosphate fertiliser production, alongside metal treatment and battery manufacture.
- Hydrochloric acid is used in vinyl chloride production for PVC, metal refining, descaling and water treatment.
- Nitric acid is both corrosive and a powerful oxidising agent, used in fertiliser and explosives manufacture, and can corrode metals that resist other acids.
- Corrosive acids require materials of construction and handling procedures specifically selected to resist the substance in use - see materials of construction.
How Acids Are Used in Manufacturing
Acids are handled through dedicated corrosive chemical processing capability, incorporated via liquid chemical blending or as reactants in reaction chemistry, and are relevant to agrochemicals and metal-treatment applications.
Regulatory Considerations
Acid handling and storage fall under COSHH, and concentrated acids may require DSEAR consideration alongside general corrosive-substance controls - see COSHH responsibilities for the framework a manufacturer should have in place.
Strength, Concentration and Handling
Two properties are often conflated and are worth separating. Strength describes how readily an acid dissociates - a fundamental chemical property. Concentration describes how much acid is present in a given volume. A dilute solution of a strong acid and a concentrated solution of a weak one behave quite differently, and both the hazard profile and the formulation effect depend on the combination rather than either alone.
For manufacturing purposes the practical consequences are containment and materials. Acids attack many common construction materials, so materials of construction throughout the system - vessel, pipework, pumps, seals and gaskets - have to be compatible. This is a frequent reason a manufacturer with apparently suitable capacity cannot take acid work, and why glass-lined reactors exist.
Reactions and Dilution
Neutralisation is strongly exothermic, and so is diluting concentrated acid. Both release substantial heat, and both must be carried out under control with adequate cooling and correct order of addition - adding water to concentrated acid rather than the reverse is the classic and genuinely dangerous error.
This means acid handling requires cooling capacity and controlled addition rather than simply corrosion-resistant plant. Where a formulation requires pH adjustment with acid, the addition rate is a real process parameter rather than a detail, and it belongs in the process specification. Acids also affect the transport and storage position, since corrosive classification brings its own dangerous goods requirements.
Concentration Supplied
Acids are supplied at a range of concentrations, and specifying the acid without the concentration leaves the formulation undefined. Concentration also affects the hazard classification, the storage requirements and the transport position, so it is worth confirming what strength the manufacturer holds - using a different concentration means adjusting the quantity, which is a formulation change rather than a substitution.
Questions to Ask a Manufacturer
- What acids do you have experience handling, and at what concentrations?
- What materials of construction do you use for acid storage and reaction vessels?
- How do you manage the safety risks of concentrated acid handling and dilution?
- Do you have dedicated corrosive-handling capability separate from your general production lines?
Related Pages
Frequently Asked Questions
Are all industrial acids equally hazardous?
No - hazard depends on the specific acid, its concentration and the process it's used in. Nitric acid's oxidising properties, for example, bring additional considerations beyond simple corrosivity that don't apply equally to every acid.
Can any contract manufacturer handle acid-based processes?
Not necessarily - acid handling requires specific materials of construction, ventilation and safety procedures, so confirm a prospective manufacturer's corrosive-handling capability rather than assuming it's standard.
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Search the DirectoryLast reviewed: August 2026. Regulation and guidance change — verify anything you rely on against the primary source. Tell us if something here is out of date.