Chemical & Engineering News Digital Edition - Institute of Materia ...
Chemical & Engineering News Digital Edition - Institute of Materia ...
Chemical & Engineering News Digital Edition - Institute of Materia ...
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SOUTHERN COPPER<br />
SULFURIC ACID is one <strong>of</strong> those unheralded<br />
lubricants that keep the gears <strong>of</strong> the<br />
industrial economy spinning. Although less<br />
in the limelight than petrochemicals such<br />
as ethylene or polyethylene, it is in fact the<br />
largest volume chemical in the world. Over<br />
the past six months, it has become a very<br />
expensive chemical as well.<br />
The spot market price for sulfuric acid<br />
sold on the U.S. Gulf Coast is four times<br />
higher today than it was a year ago. And<br />
because sulfuric acid is critical to so many<br />
manufacturing operations, the price runup<br />
is causing grief for a wide range <strong>of</strong> industrial<br />
users.<br />
The story <strong>of</strong> sulfuric acid’s rise is intertwined<br />
with the stories <strong>of</strong> metals, fertilizers,<br />
grains, and other commodities that<br />
have been skyrocketing in price in recent<br />
months because <strong>of</strong> insatiable demand from<br />
China and other developing countries. Although<br />
industry observers advance various<br />
explanations for why acid prices are rising,<br />
they all agree that some kind <strong>of</strong> market hysteria<br />
is also at work.<br />
Robert Boyd, founder <strong>of</strong> the sulfur and<br />
sulfuric acid consulting firm PentaSul, traces<br />
the run-up back to what at the time must<br />
have seemed like an inconsequential hiccup:<br />
the inability <strong>of</strong> the Phoenix-based copper<br />
company Southern Copper to get a Peruvian<br />
sulfuric acid plant up and running on time.<br />
BUSINESS<br />
THE ACID TOUCH<br />
RISING PRICES for sulfuric acid have widespread industrial impact<br />
MICHAEL MCCOY, C&EN NORTHEAST NEWS BUREAU<br />
Smelters <strong>of</strong> copper, nickel, and other<br />
metals play a pivotal role in the sulfuric<br />
acid business. Traditional refining <strong>of</strong> sulfidic<br />
copper ores creates copious amounts<br />
<strong>of</strong> sulfur dioxide gas, which most modern<br />
smelters capture and convert into sulfuric<br />
acid. Yet refining copper via the comparatively<br />
new solvent extraction/electrowinning<br />
technique requires huge quantities <strong>of</strong><br />
sulfuric acid to leach metal out <strong>of</strong> copper<br />
oxide-rich ores. Depending on their location,<br />
metal companies can be big acid sellers<br />
or big acid buyers.<br />
Early last year, Southern was set to become<br />
a big acid seller following the installation <strong>of</strong><br />
abatement equipment designed to capture<br />
more than 92% <strong>of</strong> the company’s sulfur dioxide<br />
emissions in the form <strong>of</strong> 1 million metric<br />
tons <strong>of</strong> sulfuric acid annually. However, Boyd<br />
says the plant didn’t get fully going until May.<br />
In the meantime, Southern was forced to buy<br />
sulfuric acid on the open market to satisfy the<br />
customers it had lined up.<br />
That open market, however, was becoming<br />
crowded with producers <strong>of</strong> metals and<br />
fertilizers seeking sulfuric acid for their<br />
own operations. Prices for these commodi-<br />
WWW.CEN-ONLINE.ORG 27 APRIL 14, 2008<br />
GIVE AND<br />
TAKE Refining<br />
copper,<br />
shown here<br />
at Southern<br />
Copper’s Ilo,<br />
Peru, smelter,<br />
can produce<br />
or consume<br />
sulfuric acid.<br />
ties were hitting all-time<br />
highs, and sellers were<br />
desperate to cash in while<br />
they could.<br />
Since the initial market<br />
tightening last spring,<br />
the situation has only<br />
intensified. “I have never<br />
seen anything like it, and<br />
I have been in the busi-<br />
ness for 23 years,” says Jack Weaverling,<br />
senior vice president <strong>of</strong> the Texas-based<br />
sulfuric acid marketer Shrieve <strong>Chemical</strong>.<br />
Part <strong>of</strong> the problem, Weaverling and<br />
other industry players say, is the way that<br />
disparate events are converging to drive up<br />
the price <strong>of</strong> sulfuric acid.<br />
These days, metal makers have an incentive<br />
to turn out as much copper as they can.<br />
According to the London Metal Exchange,<br />
copper is selling for more than $3.80 per<br />
lb today, compared with only about $1.40<br />
at the beginning <strong>of</strong> 2005. Many firms are<br />
turning to the solvent extraction method<br />
and need acid to run these facilities. For<br />
example, at the same time that Southern is<br />
capturing and selling acid at its new Peruvian<br />
operation, the company plans to build<br />
another copper facility in Peru that will<br />
consume more than two-thirds <strong>of</strong> that acid.<br />
EVEN CRAZIER than metals is the phosphate<br />
fertilizer market, thanks to booming<br />
global demand for corn and other foodstuffs.<br />
A World Bank report puts the average<br />
2006 price <strong>of</strong> diammonium phosphate<br />
(DAP), the most widely traded phosphate<br />
fertilizer, at $260 per metric ton on the<br />
U.S Gulf Coast. Last month, according to<br />
Penta Sul, DAP broke $1,000 per metric ton.<br />
U.S. phosphate fertilizer producers use<br />
sulfuric acid to convert phosphate rock,<br />
mined chiefly in central Florida, into phosphoric<br />
acid. Their operations account for<br />
fully 60% <strong>of</strong> U.S. sulfuric acid consumption.<br />
Although most big fertilizer producers<br />
make their own acid, times <strong>of</strong> outsized<br />
demand can prompt them to look to outside<br />
supplies. And with the returns they<br />
are getting on DAP, they can afford to pay<br />
whatever the market is charging.<br />
According to NorFalco, an Ohio-based<br />
company that markets sulfuric acid from<br />
several Canadian smelters and is one <strong>of</strong><br />
North America’s largest suppliers, fertil-<br />
Disparate events are converging to drive up<br />
the price <strong>of</strong> sulfuric acid to record highs.