This study focused on the techno-economic assessment of sulphur gas removal from coal combustion, pyrolysis and gasification in the flue gas stream in order to reduce harmful emissions from the coal industry which causes adverse effects to the environment.  A potential of valorisation of the SO₂ to valuable, sulphuric acid (H₂SO₄) is therefore analysed. The design of a 400 tpd H₂SO₄ production process utilizing sulphur from coal combustion and pyrolysis flue gases is proposed. Experiments conducted indicated a 2.12%.wt by mass of coal is the sulphur content in the flue gases. The modified Claus Process, Amine Process and the Contact Process were selected as the best processes for optimum H₂SO₄ production. Based on the mass balances, the calculated gas flow rate from the power station boilers which utilize an average of 6000 tpd of coal was 146.33 t/hr. Economic analysis showed that the production cost of a tonne of H₂SO₄ is USD 32.47 and the profit margin was USD 57.53, the return on investment (ROI) was 44%, with a payback period of 2.28 years and the breakeven point was 60 tpd indicating the viability of utilizing the recovered sulphur to produce H₂SO₄ both technically and economically.