Sulphuric acid is one of the most important chemicals used in industries such as fertilizers, batteries, chemical manufacturing, and more. If you are thinking about starting a sulphuric acid plant in India, it may sound complicated.
Step 1: Understand What a Sulphuric Acid Plant Is
A sulphuric acid plant set up is a facility where sulphuric acid (H₂SO₄) is manufactured. The production usually happens in three stages:
- Burning Sulphur – Sulphur is burned in the presence of oxygen to produce sulphur dioxide (SO₂).
- Conversion to Sulphur Trioxide – Using a catalyst, SO₂ is converted into sulphur trioxide (SO₃).
- Absorption into Water – SO₃ is absorbed in water to form concentrated sulphuric acid.
Some plants also produce chlor-alkali products like caustic soda and chlorine, which are important in many industries. So, if you plan a chlor alkali set up, the same area might serve both purposes.
Step 2: Choose the Right Location
Location is critical. Here are some points to consider:
- Close to raw materials like sulphur or gypsum.
- Near water sources because acid production uses a lot of water.
- Proper transport access for raw materials and finished products.
- Adequate space for storage and future expansion.
- Complies with local pollution control norms.
Before you finalize, you will need approvals from the Bihar State Pollution Control Board or Goa State Pollution Control Board License, depending on your location.
Step 3: Apply for Licenses and Environmental Approvals
Setting up a chemical plant in India requires proper licensing. You can’t start production without it. Here’s what you need:
3.1 State Pollution Control Board Approval
- If your plant is in Bihar, get approval from the Bihar State Pollution Control Board.
- If your plant is in Goa, you need a Goa State Pollution Control Board License.
- These approvals ensure your plant won’t harm the environment.
3.2 Factory License
- Apply to the local Factory Licensing Authority.
- They check for safety measures, building structure, and labor facilities.
3.3 Chemical Handling License
- Sulphuric acid is corrosive. You need licenses for handling, storage, and transportation.
3.4 Fire Safety Clearance
- Your local fire department will inspect fire safety systems before you start.
3.5 Explosives & Hazardous Material Clearance
- If using any explosive chemicals for production, get clearance from the Chief Controller of Explosives.
Step 4: Select the Right Machinery
Machinery is the heart of your plant. The main equipment includes:
- Sulphur Burner – Burns sulphur to produce sulphur dioxide.
- Conversion Tower (Contact Process) – Converts SO₂ to SO₃ with catalysts.
- Absorption Tower – Produces concentrated sulphuric acid.
- Storage Tanks – For raw materials and finished acid.
- Boilers & Pumps – For maintaining pressure, heat, and water flow.
For a chlor alkali set up, you also need:
- Electrolytic cells for producing chlorine and caustic soda.
- Storage for chlorine gas and caustic soda.
Always choose machines that are efficient, safe, and certified for industrial chemical production.
Step 5: Estimate Investment
The investment depends on the size of your plant:
- Small-scale plant: ₹5–10 crore
- Medium-scale plant: ₹10–25 crore
- Large-scale plant: ₹25 crore and above
Factors affecting investment:
- Machinery cost
- Land and construction
- Raw material procurement
- Labor and training
- Licensing and environmental compliance costs
Tip: Always keep a 10–15% contingency budget for unexpected expenses.
Step 6: Hire Skilled Staff
Operating a sulphuric acid plant requires trained personnel. Key staff includes:
- Plant manager with chemical engineering knowledge
- Chemists and lab technicians
- Machine operators
- Safety officers
- Environmental compliance officer
Training is very important because sulphuric acid is highly corrosive and mistakes can be dangerous.
Step 7: Follow Environmental Compliance
Environmental compliance is not just legal — it also protects workers and nearby communities.
- Effluent Treatment Plant (ETP) – Treat waste water before releasing it.
- Air Pollution Control – Install scrubbers to reduce SO₂ emissions.
- Waste Management – Dispose of solid and liquid waste safely.
- Regular Monitoring – Submit reports to the State Pollution Control Board.
Remember, ignoring compliance can lead to fines, plant shutdown, or legal action.
Step 8: Start Production
Once all approvals, machinery, and staff are in place, you can start production.
Tips for smooth operations:
- Maintain a daily log of production, safety checks, and waste.
- Monitor temperature and pressure constantly.
- Schedule regular maintenance of machines.
- Keep emergency response plans ready.
FAQ About Sulphuric Acid Plant Set Up
Q1: Can I start a sulphuric acid plant in any state of India?
A: Yes, but you must follow the rules of the local State Pollution Control Board.
Q2: How much land do I need?
A: Typically, 2–5 acres for small to medium plants. Larger plants may require more.
Q3: Is sulphuric acid production dangerous?
A: Yes, sulphuric acid is highly corrosive. Proper safety equipment and training are essential.
Q4: Can a chlor alkali set up be combined with a sulphuric acid plant?
A: Yes, many chemical plants produce both to optimize resources.
Q5: How long does it take to set up a plant?
A: On average, 12–18 months for approvals, machinery installation, and trial production.
Q6: Which licenses are mandatory?
A: Pollution control board approval, factory license, chemical handling license, and fire safety clearance are mandatory.
Author Profile
Upendra Sharma is a chemical industry consultant with over 10 years of experience helping entrepreneurs set up chemical plants in India. He specializes in licensing, machinery selection, environmental compliance monitoring , and industrial safety. Upendra has helped businesses in states like Bihar, Goa, Maharashtra, and Uttar Pradesh to legally and safely start operations.
