Industry Overview
Tobacco processing generates substantial quantities of waste, including rejected leaves, broken lamina, midribs, stalks, and stems. These by-products can be utilized for recovering valuable compounds, with nicotine and tobacco seeds being among the most important products obtainable from tobacco waste. Other potentially recoverable chemicals include nicotinic acid, nicotine sulphate, rutin, pectic substances, and certain organic acids.
Indian tobacco waste generally contains about 1–3% nicotine, and waste containing less than 2% nicotine can also be utilized. A process developed by the National Chemical Laboratory, Poona, enables recovery of approximately 95% of the nicotine present in tobacco waste as nicotine sulphate. The process involves macerating tobacco waste with water and lime, followed by steam distillation. The resulting distillate is neutralized with sulphuric acid and concentrated.
Nicotine sulphate has historically been used as a contact insecticide and is principally effective as a fumigant, with additional stomach-poison action. It has applications against various agricultural pests, particularly soft-bodied insects. The report covers the properties, chemistry, standards, manufacturing processes, raw materials, plant and machinery, safety considerations, testing procedures, market aspects, suppliers, and commercial applications associated with nicotine sulphate and nicotine recovery from tobacco waste.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 20 Kg./Day |
| Land & Building (600 sq.mt.) | Rs. 69 Lac |
| Plant & Machinery | Rs. 11 Lac |
| Working Capital for 1 Month | Rs. 11 Lacs |
| Total Capital Investment | Rs. 95 Lac |
| Rate of Return | 37% |
| Break Even Point | 58% |
Content Index
- INTRODUCTION
- USES AND APPLICATIONS
- PROPERTIES
- HAZARD AND SHIPPING REGULATION:-
- PROPERTIEAS AND STRUCTURE OF NICOTINE
- STRUCTURE OF NICOTINE
- STRUCTURE OF NICOTINE
- 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%
- SPECIFICATION
- CHEMICAL COMPOSITION:
- MODE OF ACTION:
- USES:
- CHEMICAL FORMULA:
- ADVANTAGES:
- NICOTINE SULPHATE 40%
- MARKET OF NICOTINE SULPHATE
- MARKET OVERIEW OF NICOTINE SULPHATE
- 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
- RECOMMENDATIONS:
- PRESENT MANUFACTURERS/SUPPLIERS OF NICOTINE SULPHATE
- MARKET OVERVIEW OF TOBACOO
- 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 OF NICOTINE SULPHATE (40%)
- MANUFACTURING PROCESS OF NICOTINE 95% (INTERMEDIATE TO ANUFACTURE NICOTINE USP/EP)
- MASS BALANCE OF NICOTINE 95%
- MANUFACTURING PROCESS OF NICOTINE (PURE) USP
- MASS BALANCE OF NICOTINE USP/EP
- PROCESSING DETAILS OF NICOTINE (USP)
- PROCESS FLOW DIAGRAM
- MANUFACTURING PROCESS IN DETAIL
- 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)
- RECOVERY OF SOLVENT
- IMPLEMENTATION SCHEDULE:-
- EXTRACTION OF ALKALOIDS
- ISOLATION OF NICOTINE
- ISOLATION OF NICOTINE
- OPTIMIZATION OF NICOTINE SULPHATE
- 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 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 AND MACHINERY [GLOBAL]
- 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 by recovering nicotine from tobacco waste and reacting the recovered nicotine-containing distillate with sulphuric acid. The report describes tobacco waste such as rejected leaves, broken lamina, midribs, stalks, and stems as raw material sources. The waste is macerated with water and lime and subjected to steam distillation, after which the distillate is neutralized with sulphuric acid and concentrated to produce nicotine sulphate.
Nicotine sulphate has been used primarily as an agricultural insecticide, particularly against soft-bodied and minute pests. The report identifies aphids, white flies, leaf hoppers, thrips, red spiders, snails, slugs, and cabbage butterfly larvae among the pests against which it can be effective. It is described as a contact insecticide that can also act principally as a fumigant and, in some circumstances, as a stomach poison.
Nicotine is recovered from tobacco waste through extraction followed by steam distillation and concentration. The described process begins with maceration of tobacco waste using water and lime. Steam is then used to distill the nicotine-containing components, producing a distillate that can be neutralized with sulphuric acid. Subsequent concentration produces nicotine sulphate. The report also discusses alternative extraction, separation, purification, distillation, testing, and packing stages for nicotine products.
The principal raw material is tobacco leaf by-product or tobacco waste containing recoverable nicotine. The report also identifies lime and sulphuric acid as important materials in the described nicotine sulphate process. Depending on the specific manufacturing route, additional materials may be required for extraction, purification, testing, and processing. The report separately covers suppliers of tobacco waste, benzene, lime powder, and other inputs associated with the described processes.
Equipment for nicotine recovery and nicotine sulphate production can include steam distillation kettles, concentration chambers, concentration flasks, reaction vessels, industrial filters, distillation units, evaporators, tray dryers, digester tanks, crystallization trays, centrifuges, storage tanks, water softening plants, steam boilers, generators, packing machines, conveyors, and material-handling equipment. The exact equipment configuration depends on the selected process, product specification, scale, and required purification stages.
Nicotine sulphate production requires controlled handling of nicotine-containing materials and process chemicals, supported by appropriate storage, personal protective equipment, ventilation, process controls, and emergency procedures. The report includes hazard information for benzene, lime, and sulphuric acid, along with a material safety data sheet covering chemical identification, physical identification, hazards, toxicity, stability, preventive steps, first aid, and storage and handling. Industrial operations should follow applicable safety, environmental, transport, and chemical-handling requirements.
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