Hydrochloric acid is an aqueous solution of hydrogen chloride gas. It is produced primarily by four basic methods: the chlorination of organic chemicals; the combination of hydrogen and chlorine; the salt-sulfuric acid production process; and, as a co-product in the manufacture of silica. In most cases, hydrochloric acid is produced from the chlorination of organic chemicals with much smaller amounts derived from the other processes. Most of the hydrochloric acid produced in the U.S., Europe, and Japan is generated as a by-product in the manufacture of a wide variety of organic chemicals via chlorination reactions. This supply depends largely on demand for the primary products. A significant amount of by-product hydrochloric acid is generated when ethylene dichloride (EDC) is cracked to make vinyl chloride monomer (VCM). This hydrochloric acid is usually recycled back to the EDC reactor for additional oxychlorination and for the most part, does not enter the commercial market. Similarly, most of the hydrochloric acid generated in the production of chlorinated C1s (primarily methylene chloride and chloroform) is recycled to produce additional methyl chloride.
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Demand Outlook
The global hydrochloric acid market is valued at USD 1 billion in 2020 and it is expected to grow at a CAGR of 5% from 2021 to 2027 due to increasing demand from food processing and oil & gas industries. Globally, nearly 37% of all hydrochloric acid consumption is for the production of EDC, and 61% is used in the production of organic compounds, most of which is captive consumption. The remaining consumption is in several inorganic or merchant applications. APAC is leading the global hydrochloric acid market in terms of consumption due to rapid industrial expansion in China, Indonesia, and India. China is expected to witness the fastest growth due to rising ore processing, calcium chloride & ethyl dichloride production, oil & gas industry over the forecast period.
Cost Drivers
Hydrochloric acid can be produced as a by-product for about 40 chemical processes across multiple industries. Hence, the fixed cost of chemical processing including material costs, equipment costs, maintenance costs considered as the major cost drivers of hydrochloric acid production. Moreover, suppliers try to reduce variable costs by outsourcing the production activity in low-cost sourcing destinations like India and China. As these countries offer cheap labor, it significantly reduces the overall cost of one unit of hydrochloric acid production and increases the profit margin.
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