Code #4034
Industry Overview
Tobacco cultivation, harvesting, processing, and manufacturing generate substantial quantities of waste, including rejected leaves, broken lamina, midribs, stalks, and stems. These materials can be utilized as valuable sources of nicotine and other commercially useful constituents. Tobacco waste may also yield nicotine acid, nicotine sulphate, rutin, pectic substances, and certain organic acids.
Indian tobacco waste generally contains approximately 1–3% nicotine, and waste containing less than 2% nicotine can also be utilized for recovery. A process developed by the National Chemical Laboratory, Poona, enables substantial recovery of nicotine from tobacco waste in the form of nicotine sulphate. The process involves maceration of tobacco waste with water and lime, steam distillation, neutralization of the distillate with sulphuric acid, and concentration.
Nicotine sulphate has been used extensively for controlling insect pests of agricultural importance and can be manufactured from tobacco waste as well as liquors generated during the production of chewing and smoking tobacco. The report also covers nicotine derivatives, including nicotine alkaloid, nicotine polacrilex, and nicotine bitartrate dihydrate, together with their properties, applications, specifications, manufacturing processes, testing methods, raw materials, plant and machinery requirements, market aspects, safety considerations, and implementation planning.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 1.4446 MT/Day |
| Land & Building (10,000 sq.mt.) | Rs. 5.54 Cr |
| Plant & Machinery | Rs. 2.70 Cr |
| Working Capital for 1 Month | Rs. 13.72 Cr |
| Total Capital Investment | Rs. 22.34 Cr |
| Rate of Return | 74% |
| Break Even Point | 25% |
Content Index
- INTRODUCTION
- USES AND APPLICATION OF NICOTINE BITARTRATE DIIHYDRATE
- USES AND APPLICATIONS OF NICOTINE SULPHATE
- PROPERTIES OF NICOTINE SULPHATE
- HAZARD AND SHIPPING REGULATION
- APPLICATION OF NICOTINE POLACRILEX
- ADVANTAGE OF NICOTINE POLACRILEX
- NICOTINE POLACRILEX/RESINATE USP/EP 20%
- NICOTINE POLACRILEX/RESINATE USP/EP 15%
- PHYSIOLOGY & TECHNOLOGY OF NICOTINE
- B.I.S. SPECIFICATION
- 1. SCOPE
- 2. REQUIREMENTS
- 3. PACKING AND MARKING
- 4. SAMPLING
- 5. TESTS
- DETERMINATION OF NICOTINE CONTENT
- A - 1 METHOD
- A - 2 REAGENTS
- A - 3 PROCEDURE
- SEDIMENTATION TEST
- B - 1 PROCEDURE
- B - 2 REPORT
- NICOTINE SULPHATE 40%
- SPECIFICATION
- CHEMICAL COMPOSITION:
- MODE OF ACTION:
- USES:
- CHEMICAL FORMULA:
- ADVANTAGES:
- NICOTINE SULPHATE 40%
- USES AND APPLICATION OF NICOTINE ALKALOID 95%
- NICOTINE ALKALOID 95%
- SPECIFICATIONS
- OTHER INFORMATION
- PROPERTIES OF NICOTINE POLACRILEX 20%
- PRODUCT SPECIFICATION:
- COMPOSITION:
- OVERVIEW OF NICOTINE SULPHATE
- PRODUCTION OF PESTICIDES IN INDIA
- NICOTINE MARKET IN INDIA
- PRODUCTS FROM TOBACCO AND TOBACCO WASTES:
- NICOTINE / NICOTINE DERIVATIVES FROM TOBACCO:
- NICOTINE AND ITS COMMERCIALLY IMPORTANT DERIVATIVES:
- WORLD PESTICIDE MARKET AND PROSPECTS FOR NICOTINE SULPHATE
- STATUS OF TOBACCO WASTE BASED INDUSTRIES IN INDIA
- OVERVIEW OF TECHNOLOGIES FOR NICOTINE BASED PRODUCTS
- NEED FOR DEVELOPMENT OF ALTERNATE USE FOR TOBACCO:
- [COMMERCIALLY IMPORTANT APPLICATIONS]:
- A LOOK AT THE ORGANS OF THE BODY HARMED BY TOBACCO SMOKE
- PHARMACEUTICAL USE OF NICOTINE:
- COMMERCIAL ASPECTS OF NICOTINE SULPHATE & NICOTINE DERIVATIVES
- MARKET PRICES OF NICOTINE AND ITS SALTS:
- CONCLUSIONS AND RECOMMENDATIONS:
- RECOMMENDATIONS:
- MARKET OVERVIEW OF NICOTINE GUMS
- PRESENT MANUFACTURERS/SUPPLIERS OF NICOTINE BASED PRODUCTS
- CHEMICAL COMPOSITION OF TOBACCO
- CHEMISTRY OF NICOTINE
- THE DISTILLATION AND CONCENTRATION INSTALLATION WAS BUILT UP AS FOLLOWS
- (1) THE STEAM DISTILLATION KETTLE.
- (2) THE STEAM-HEATED NICOTINE CONCENTRATION CHAMBER.
- (3) THE NICOTINE CONCENTRATIOIN FLASKS.
- (D) THE DISTILLATION AND CONCENTRATION PROCESS.
- (1) THE CONCENTRATION OF THE ACID IN THE FLASKS.
- (2) THE TEMPERATURE OF THE CONCENTRATION CHAMBER
- (3) THE DLSTILLATION PERIOD.
- (4) THE AMMONIUNN SULPHATE FORMED IN 'THE RECEIVING FLASKS.
- (5) THE SEPARATION OF THE AMMONIUM SULPHATE AND NECOTINE ULPHATE
- VALUE OF BY PRODUCTS.
- THE EXTRACTED TOBACCO RESIDUE.
- COMMERCIAL
- CHARACTERISTICS & APPLICATION OF NICOTINE
- MODE ACTION
- ZONES OF CULTIVATION OF TOBACCO
- RAW MATERIALS
- TOBACCO
- CULTIVATION
- SOWING AND GROWTH
- HARVEST
- GLOBAL PRODUCTION
- TRENDS
- MAJOR PRODUCERS
- UNITED STATES
- CHINA
- BRAZIL
- INDIA
- BENZENE
- HAZARD
- LIME
- HAZARD
- SULFURIC ACID
- HAZARD
- TOBACCO LEAF BY-PRODUCTS (TOBACCO WASTE)
- MANUFACTURING PROCESS OF NICOTINE USP/EP
- MASS BALANCE PER BATCH
- MASS BALANCE PER MONTH
- MANUFACTURING PROCESS OF NICOTINE POLACRILEX (USP/EP)
- MASS BALANCE PER BATCH
- MASS BALANCE PER BATCH
- MANUFACTURING PROCESS OF NICOTINE BITARTRATE DIHYDRATE
- CHEMICAL REACTION
- MASS BALANCE PER MONTH
- MANUFACTURING PROCESS OF NICOTINE 95%
- MASS BALANCE PER BATCH
- MASS BALANCE PER MONTH
- MANUFACTURING PROCESS NICOTINE SULPHATE (40%)
- PROCESS DETAILS OF NICOTINE (USP)
- PROCESS FLOW DIAGRAM
- PROCESS FLOW SHEET FOR NICOTINE SULPHATE FROM TOBACCO WASTE
- IMPLEMENTATION SCHEDULE
- MATERIAL SAFETY DATA SHEET OF NICOTINE SULPHATE 40%
- TESTING METHOD OF NICOTINE AND NICOTINE SULPHATE
- EXAMPLE L
- STAGE 1 HARVESTING AND DEEP FREEZING
- STAGE II MIXING AND PERCOLATION
- STAGE III EXTRACTION
- STAGE IV SEPARATION
- STAGE V FILTRATION AND PURIFICATION
- STAGE VI TESTING
- STAGE VII PACKING
- EXAMPLE 2
- STAGE 1 MIXING
- STAGE II PERCOLATION
- STAGE III EXTRACTION
- STAGE IV SEPARATION
- STAGE V FILTRATION AND PURIFICATION
- STAGE VI PACKING
- STAGE VII ALKALIZATION
- STAGE VIII PURIFICATION OF NICOTINE ALKALOID
- STAGE IX DISTILLATION OF NICOTINE ALKALOID
- STAGE X TESTING.
- STAGE XI PACKING
- EXAMPLE 3
- STAGE 1 MIXING
- STAGE II MIXING AND PERCOLATION
- STAGE III EXTRACTION
- STAGE IV SEPARATION
- STAGE V FILTRATION AND PURIFICATION
- STAGE VI PACKING
- STAGE VIII PURIFICATION OF NICOTINE ALKALOID
- STAGE IX DISTILLATION OF NICOTINE ALKALOID
- STAGE X TESTING.
- STAGE XI PACKING
- EXAMPLE 4
- STAGE 1 MIXING
- STAGE II PERCOLATION
- STAGE III EXTRACTION
- STAGE IV SEPARATION
- STAGE V FILTRATION AND PURIFICATION
- STAGE VI PACKING
- STAGE VII ALKALIZATION
- STAGE VIII PURIFICATION OF NICOTINE ALKALOID
- STAGE IX DISTILLATION OF NICOTINE ALKALOID
- STAGE X TESTING
- STAGE XI PACKING
- EXAMPLE 5
- STAGE I WASHINGS OF THE INSOLUBLE FRACTION
- STAGE II CENTRIFUGATION AND DRYING OF INSOLUBLE FRACTION
- STAGE III CENTRIFUGATION AND DRYING OF INSOLUBLE FRACTION
- STAGE IV RECONSTITUTION OF THE TOBACCO BY IMPREGNATION
- STAGE V TESTING OF THE TOBACCO
- STAGE VI PACLDNG
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF TOBACCO WASTE
- SUPPLIERS OF BENZENE
- SUPPLIERS OF LIME POWDER
- SUPPLIERS OF PLANT & MACHINERY
- SUPPLIERS OF REACTION VESSEL
- SUPPLIERS OF INDUSTRIAL FILTERS
- SUPPLIERS OF DISTILLATION UNITS
- SUPPLIERS OF EVAPORATORS
- SUPPLIERS OF TRAY DRYER
- SUPPLIERS OF DIGESTER TANKS
- SUPPLIERS OF CRYSTALLIZATION TRAY
- SUPPLIERS OF CENTRIFUGE MACHINE
- SUPPLIERS OF STORAGE TANK
- SUPPLIERS OF WATER SOFTENING PLANT
- SUPPLIERS OF STEAM BOILERS
- SUPPLIERS OF GENERATOR (D.G. SET)
- SUPPLIERS OF PACKING MACHINE
- SUPPLIERS OF CONVEYOR BELT
- SUPPLIERS OF ELEVATORS, ESCALATORS
Appendix
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Nicotine sulphate can be manufactured by recovering nicotine from tobacco waste and converting it into a sulphate salt. The report describes tobacco waste such as rejected leaves, broken lamina, midribs, stalks, and stems as raw material sources. The process involves maceration with water and lime, steam distillation of the nicotine-containing extract, neutralization of the distillate with sulphuric acid, and concentration. The resulting nicotine sulphate is described as a product used in agricultural pest-control applications.
Yes, tobacco waste can be used as a source of recoverable nicotine. The report identifies rejected leaves, broken portions of lamina, midribs, stalks, and stems as potentially useful materials. It states that Indian tobacco waste generally contains approximately 1–3% nicotine and that waste containing even less than 2% nicotine can be utilized. Recovery depends on the characteristics of the feed material and the selected extraction and purification process. Proper handling, process control, and safety measures are essential because nicotine and associated chemicals can present significant hazards.
The main process steps described in the report are tobacco waste maceration, extraction with water and lime, steam distillation, acid neutralization, and concentration. During maceration and extraction, nicotine is transferred from the tobacco material into the liquid phase. Steam distillation is then used to recover nicotine-containing distillate. Sulphuric acid is used for neutralization, producing nicotine sulphate, followed by concentration. The report also provides process flow information, mass-balance sections, testing methods, and detailed process examples for nicotine-based products.
Tobacco and tobacco waste can serve as sources of nicotine and several nicotine derivatives and other constituents. The report covers nicotine sulphate, nicotine alkaloid, nicotine polacrilex or resinate, and nicotine bitartrate dihydrate. It also discusses nicotine acid, rutin, pectic substances, and certain organic acids as potential products or constituents obtainable from tobacco waste. The commercial suitability of each product depends on its required purity, specification, application, processing technology, quality control requirements, and applicable safety and regulatory considerations.
Equipment requirements depend on the specific nicotine product and manufacturing route. The report identifies equipment and systems including reaction vessels, industrial filters, distillation units, evaporators, tray dryers, digester tanks, crystallization trays, centrifuge machines, storage tanks, water softening plants, steam boilers, generators, packing machines, and conveyor belts. A complete plant may also require suitable extraction, separation, purification, testing, storage, and material-handling facilities. Equipment selection should be based on process design, material compatibility, capacity, operating conditions, safety requirements, and product specifications.
Nicotine sulphate manufacturing requires strict control of hazardous materials, process conditions, storage, handling, and worker exposure. The report specifically includes hazard information for benzene, lime, sulphuric acid, and tobacco-related materials, as well as a Material Safety Data Sheet for nicotine sulphate 40%. Appropriate engineering controls, personal protective equipment, ventilation, chemical storage practices, emergency procedures, waste management, and product-specific safety documentation should be incorporated into plant design and operations. Applicable industrial, environmental, transport, and chemical-handling requirements should also be evaluated before commercial production.
The report covers specifications, sampling, testing, nicotine-content determination, and sedimentation testing for nicotine-related products. It includes sections associated with B.I.S. specifications, including scope, requirements, packing and marking, sampling, and tests. It also provides procedures and reagents for determining nicotine content and discusses testing methods for nicotine and nicotine sulphate. Quality control should verify the product against its applicable specification and intended application, with appropriate sampling, analytical procedures, documentation, and batch-release controls incorporated into the manufacturing system.
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