Energy consumption - As mentioned above, sulfuric acid must be kept at elevated temperature while hydrochloric is used at ambient temperature. ( hydrochloric must be 70F or above to pickle at an acceptable rate so that some heating may be required in the winter months )
Operator Skill - Because of its nature, sulfuric acid, even when used with an inhibitor, will work its way under the surface rust or scale and attack the base metal of the article being pickled. On the other hand, hydrochloric with the proper inhibitor will remove rust or scale and not attack the base metal. This means that an article may be left in hydrochloric acid solution for extended times without damage and therefore is easier for an operator to use.