Sulfuric acid is a common ingredient in many household products, such as drain cleaners and certain fertilizers. It’s also widely used in industries like pharmaceuticals and detergent manufacturing. However, the Occupational Safety and Health Administration (OSHA) has documented numerous incidents highlighting the dangers of sulfuric acid exposure. Due to its toxic nature and potential hazards, a comprehensive safety guide is essential to ensure safe handling and prevent accidents.  

 

Despite its vital role in manufacturing and chemical processes, sulfuric acid poses serious health risks if not handled properly due to its highly corrosive nature. If your organization regularly deals with this hazardous substance, it’s essential to understand the risks and safety measures. Keep reading this blog for a comprehensive hazard safety guide on how to manage sulfuric acid safely. 

 

Sulfuric Acid  

 

Sulfuric acid (H₂SO₄) is a highly corrosive mineral acid. Mainly it is known for its strong acidic properties and wide use in industrial applications.  

To get a better understanding check out its features below:  

  • Appearance and Properties: It is a colorless, odorless, and thick liquid. This substance readily absorbs moisture from the air due to its hygroscopic nature. 
  • Heat Generation: When mixed with water, sulfuric acid releases heat. That’s why careful handling is essential.  
  • Dissociation in Water: Sulfuric acid is a powerful acid that fully breaks down in water. It produces hydronium ions (H₃O⁺) and hydrogen sulfate ions (HSO₄⁻). These hydrogen sulfate ions can further split into sulfate ions (SO₄²⁻).  

 

Uses of Sulfuric Acid:

Sulfuric acid is one of the most widely used industrial chemicals. Below we have discussed some of its key usage. Check them out to know more about how sulfuric acid is used.  

 

  • Manufacturing Fertilizer:  

It is mainly used in making fertilizers. Many organizations use this to produce phosphoric acid and ammonium sulfate.  

 

  • Chemical Manufacturing:  

Sulfuric acid plays a crucial role as a key ingredient in the production of several important chemicals, including hydrochloric acid, nitric acid, and synthetic detergents. It is also essential in the manufacturing of dyes, pigments, and pharmaceuticals. 

 

  • Metal Processing and Treatment:  

Sulfuric acid is widely used in the metal industry to clean and prepare surfaces by removing impurities like rust. This treatment, known as “pickling”. This process is crucial for getting metals ready for finishing processes such as plating or coating. 

 

  • Lead-Acid Batteries:  

It is a key component in lead-acid batteries. Such types of batteries are commonly found in vehicles, where they act as electrolyte.  

 

  • Oil Refining and Wastewater Treatment:  

 Sulfuric acid is an essential component in petroleum refining operations. It plays a key role in treating wastewater from these processes. It helps neutralize alkaline compounds effectively. Most importantly, it aids in the elimination of impurities from the wastewater. 

 

  • Cleaning Agents:  

 Sulfuric acid’s strong acidity makes it effective for cleaning tasks. It is commonly used in drain cleaners and descaling agents to remove mineral deposits. 

 

Hazards Associated with Sulfuric Acid:

 

Many incidents have shown that exposure to sulfuric acid can cause severe burns and have both short-term and long-term health effects. Below, we detail these impacts for a better understanding. 

 

1) Skin Contact: 

 Sulfuric acid can cause serious burns if it touches the skin. It reacts with moisture, producing heat that can damage deep tissues. Long-term exposure may also lead to ongoing skin problems. 

 

2) Eye Damage:  

 Employees must be extra careful to protect their eyes when handling sulfuric acid. If it splashes into the eyes, it can cause serious damage right away, leading to pain, redness, and even permanent blindness if not treated quickly. 

 

3) Inhalation Risks:  

 Breathing in sulfuric acid fumes or mist can irritate the respiratory tract. It can cause coughing, difficulty breathing, and throat irritation. Chronic exposure can lead to more serious respiratory issues, including chronic bronchitis and lung damage. 

 

4) Reactivity with Other Substances: 

 Sulfuric acid can react aggressively with various substances, including metals, organic materials, and certain chemicals. These reactions can create dangerous situations. For instance, explosions or the release of toxic gases posing serious risks to safety are some of the common instances.  

 

Some Instances of Accidents Due to Sulfuric Acid:

 

Sulfuric acid poses significant risks to human health, and several incidents recorded by OSHA highlight its dangers. Here are a few real-life cases that demonstrate the harmful effects of sulfuric acid exposure. Check them out below. 

 

Incident #1:  

On November 9, 2020, an employee sustained chemical burns after a sulfuric acid discharge line ruptured, spraying acid onto their face, chest, and leg. The employee was hospitalized and later referred to a skin surgeon for further evaluation. 

Source Link: https://www.osha.gov/ords/imis/accidentsearch.accident_detail?id=125704.015 

 

Incident# 2: 

On December 27, 2019, a driver delivering sulfuric acid experienced a leak from the fill line, causing acid to spray under his face shield. He was hospitalized with chemical burns, but no safety violations were found during the investigation. 

Source Link: https://www.osha.gov/ords/imis/accidentsearch.accident_detail?id=125704.015 

 

Incident# 3: 

On February 9, 2019, an employee fell into a steel pickling tank containing 160°F sulfuric acid while attempting to collect a sample. He remained submerged for about a minute and suffered fatal chemicals and thermal burns. 

Source Link: https://www.osha.gov/ords/imis/accidentsearch.accident_detail?id=114473.015 

 

Safety Tips to handle the Hazards of Sulfuric Acids: 

 No matter how challenging the situation may seem, it can be managed with the right precautions. Organizations should equip their teams by providing proper safety training and first aid guidance. To reduce the risks of handling sulfuric acid, be sure to follow these essential safety tips: 

 

1) Personal Protective Equipment (PPE) 

Employees involved should wear the appropriate personal protective equipment (PPE) when working with sulfuric acid. This includes: 

  • Safety Goggles or Face Shield: Protects the eyes from accidental splashes. 
  • Acid-resistant Gloves: Ensures that the hands are shielded from acid burns. 
  • Protective Clothing: Shields the skin from potential contact. 
  • Respirator: When working in environments with sulfuric acid fumes, wearing a respirator is essential. It helps to avoid inhaling hazardous vapors. 

 

Tip: Check all the PPEs that your organization offers regularly for any signs of wear. Also, replace them when necessary. 

 

2) Proper Handling and Storage 

  • Use Designated Containers: Find appropriate containers to store the sulfuric acid at your organization. Store sulfuric acid in clearly labeled, corrosion-resistant containers made of glass, certain plastics, or other materials designed to hold acidic substances. 
  • Avoid Diluting Improperly: Always pour sulfuric acid into water, not the other way around. Adding acid to water causes a lot of heat and can make the mixture splash, which is dangerous. 
  • Store in Well-Ventilated Areas: Keep this type of toxic product in a cool, dry, and well-ventilated area. It should be kept away from incompatible substances (such as organic materials, bases, or metals). 

Tip: Clearly mark all areas where sulfuric acid is stored to prevent accidental exposure. 

 

3) Safe Transfer and Dispensing 

  • Slow and Steady: When transferring sulfuric acid, always work slowly and steadily. This is a perfect approach to avoid splashes or spills. 
  • Use Mechanical Aids: Employ pumps, siphons, or other mechanical devices to minimize human contact during transfer. 
  • Work at Waist Level: Ensure containers are at a comfortable working height. This type of practice allows workers to avoid overextending and risking accidental spills. 

Tip: Always have a neutralizing agent, such as sodium bicarbonate or lime, on hand to contain small spills immediately. 

 

4) Ventilation and Fume Control:

  • Use Fume Hoods: If sulfuric acid vapors are a concern, always suggest your employees work in a well-ventilated area. They can preferably choose a chemical fume hood to prevent inhalation of dangerous fumes. 
  • Ventilate Enclosed Spaces: For enclosed areas, ensure proper ventilation to disperse any acid vapors. It helps avoid inhalation hazards. 

 

Tip: Install sensors or detectors for sulfuric acid fumes in areas where vapor might build up, like industrial sites. 

 

5) Emergency Response and First Aid 

 

  • Eye Exposure: In case of eye contact, immediately flush the eyes with water for at least 15 minutes. For extreme cases, seek medical attention. 
  • Skin Contact: Remove contaminated clothing and thoroughly rinse the affected area with water for 15–20 minutes. Medical attention is necessary for chemical burns. 
  • Inhalation: If sulfuric acid fumes are inhaled, move to fresh air immediately. Also, seeking medical advice is suggested if breathing difficulties arise. 

Tip: Ensure all employees know the location of safety showers and eye wash stations and conduct regular safety drills. 

 

6) Labeling and Hazard Communication 

 

  • Clear Labeling: Make sure all containers are clearly labeled with hazard symbols.  It must also carry the warnings for sulfuric acid. 
  • Safety Data Sheets (SDS): Provide all employees with access to the SDS to help them get crucial hazard and safety information. 
  • Training: Regularly train employees in proper sulfuric acid handling, PPE usage, and emergency procedures. 

 

Tip: Incorporate routine safety audits and refreshers on sulfuric acid handling in your workplace safety programs. 

 

7) Neutralization and Disposal:

 

  • Neutralize Before Disposal: Sulfuric acid must be neutralized before disposal. It helps to minimize environmental impact. Use appropriate neutralizing agents such as sodium bicarbonate or calcium hydroxide to safely dilute and neutralize the acid. 
  • Follow Local Regulations: Adhere to your local, state, and federal regulations for hazardous waste disposal to avoid penalties and ensure safety. 

Tip: Consult with waste disposal professionals for large quantities to ensure compliance and safety. 

 

Conclusion:

 If your organization uses sulfuric acid regularly or will need it soon, ensure you’re prepared to manage its risks. All employees who handle sulfuric acid should receive thorough training on its hazards. By educating your team about the proper handling procedures, you can mitigate the risks associated with this hazardous substance and ensure a safer work environment.