Code #3927
Industry Overview
Tobacco processing generates substantial quantities of waste materials, including rejected leaves, broken lamina, midribs, stalks, and stems. These residues can be utilized to recover valuable by-products, with nicotine and tobacco seeds being among the most important. Other compounds such as nicotine acid, nicotine sulphate, rutin, pectic substances, and certain organic acids can also be obtained from tobacco waste.
Indian tobacco waste typically contains about 1–3% nicotine, and waste containing less than 2% nicotine can also be utilized. The report describes a simple and economical process developed by the National Chemical Laboratory, Poona, for recovering approximately 95% of the nicotine present in tobacco waste as nicotine sulphate. The process has been commercially exploited by tobacco by-product manufacturers.
Nicotine sulphate is used extensively for controlling insect pests of agricultural importance. It can be manufactured from waste tobacco as well as liquors generated during the production of chewing and smoking tobacco. The described process involves macerating waste tobacco with water and lime, steam distillation, neutralization of the distillate with sulphuric acid, and subsequent concentration.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 68.2 MT/Day |
| Land & Building (6000 sq.mt.) | Rs. 2.68 Cr |
| Plant & Machinery | Rs. 85 Lac |
| Working Capital for 1 Month | Rs. 4.92 Cr |
| Total Capital Investment | Rs. 8.57 Cr |
| Rate of Return | 42% |
| Break Even Point | 38% |
Content Index
- INTRODUCTION
- USES AND APPLICATIONS
- PROPERTIES
- HAZARD AND SHIPPING REGULATION:-
- PHYSIOLOGY & TECHNOLOGY OF NICOTINE
- B.I.S. SPECIFICATION
- 1. SCOPE
- 2. REQUIREMENTS
- 3. PACKING AND MARKING
- 4. SAMPLING
- 5. TESTS
- APPENDIX -A
- DETERMINATION OF NICOTINE CONTENT
- A - 1 METHOD
- A - 2 REAGENTS
- APPENDIX - B
- SEDIMENTATION TEST
- B - 1 PROCEDURE
- B - 2 REPORT
- NICOTINE SULPHATE 40%
- CHEMICAL COMPOSITION:
- MODE OF ACTION:
- USES:
- CHEMICAL FORMULA:
- ADVANTAGES:
- NICOTINE SULPHATE 40%
- MARKET 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:
- 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:
- PRESENT MANUFACTURERS/SUPPLIERS OF NICOTINE SULPHATE
- CHEMICAL COMPOSITION
- 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 SULPHATE
- 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 NICOTINE SULPHATE (40%)
- MANUFACTURING PROCESS OF NICOTINE (USP)
- PROCESS FLOW DIAGRAM
- MANUFACTURING PROCESS IN DETAILS
- EXTRACTION OF NICOTINE BY MEANS OF STEAM:-
- PROCESS FLOW SHEET FOR NICOTINE SULPHATE FROM TOBACCO WASTE
- PRODUCTION OF NICOTINE SULFATE FROM TOBACCO WASTE
- NICOTINE SULPHATE (MANUFACTURING PROCESS)
- A) REMOVAL FROM THE RAW MATERIAL BY WATER:-
- B) I. DIRECT REMOVAL FROM THE RAW MATERIAL STEAM:-
- III. DESTRUCTIVE DISTILLATION
- RECOVERY OF SOLVENT
- IMPLEMENTATION SCHEDULE:-
- OPTIMIZATION OF NICOTINE SUPPHATE
- MATERIAL SAFETY DATA SHEET OF NICOTINE SULPHATE 40 %
- SECTION 1. CHEMICAL IDENTIFICATION
- SECTION 2. PHYSICAL IDENTIFICATION
- SECTION 3. HAZARDS IDENTIFICATION
- SECTION 4. TOXICITY DATA
- SECTION 5. STABILITY
- SECTION 6. PREVENTIVE STEPS
- SECTION 7. FIRST AID MEASURES
- SECTION 8. STORAGE & HANDLING
- 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
- BUYER’S LIST OF NICOTINE SULPHATE
- BUYER’S OF NICOTINE SULPHATE
Appendix
- APPENDIX – A:
- 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 from tobacco waste containing recoverable nicotine. The report specifically describes the use of rejected leaves, broken lamina, midribs, stalks, and stems as raw materials. Tobacco waste is processed to extract nicotine, which is subsequently converted into nicotine sulphate through treatment with sulphuric acid. This approach provides a way to utilize tobacco-processing residues and recover a commercially useful by-product.
Nicotine can be recovered from tobacco waste through extraction followed by distillation and concentration. The process described in the report involves macerating waste tobacco with water and lime, followed by steam distillation. The nicotine-containing distillate is then neutralized with sulphuric acid and concentrated to produce nicotine sulphate. The report also discusses alternative extraction approaches and detailed stages involving mixing, percolation, extraction, separation, filtration, purification, testing, and packing.
Nicotine sulphate has historically been used as an insect-control product in agriculture. The report states that it is extensively used for controlling insect pests of agricultural importance. Its activity is associated with nicotine, an alkaloid that affects the nervous system of insects. Because nicotine compounds are toxic and require careful handling, their production, storage, transport, and application must be managed according to applicable safety and regulatory requirements.
Tobacco waste suitable for nicotine recovery can include rejected leaves, broken pieces of lamina, midribs, stalks, and stems. The report notes that Indian tobacco waste commonly contains approximately 1–3% nicotine and indicates that material containing even less than 2% nicotine can be utilized. The suitability of a particular waste stream depends on its nicotine content, physical characteristics, contamination, moisture, and the extraction technology selected.
Equipment requirements depend on the selected process configuration. The report identifies a steam distillation kettle, steam-heated nicotine concentration chamber, and nicotine concentration flasks as key components of the distillation and concentration installation. It also includes supplier categories for reaction vessels, industrial filters, distillation units, evaporators, tray dryers, digester tanks, crystallization trays, centrifuges, storage tanks, boilers, generators, packing machines, conveyors, and water-softening plants.
Nicotine sulphate production requires strict control of chemical exposure, process conditions, storage, handling, and emergency procedures. The report includes dedicated sections covering hazards, toxicity data, stability, preventive steps, first aid, and storage and handling. It also identifies benzene, lime, and sulphuric acid among process-related materials and provides separate hazard headings. Industrial facilities should use appropriate containment, ventilation, personal protective equipment, chemical compatibility controls, and applicable safety regulations.
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