Industry Overview
Tobacco processing generates substantial quantities of waste, including rejected leaves, broken lamina, midribs, stalks, and stems. These materials can be utilized to recover commercially valuable by-products, particularly nicotine and tobacco seeds. Tobacco waste may also serve as a source of nicotine acid, nicotine sulphate, rutin, pectic substances, and certain organic acids.
The report notes that Indian tobacco waste generally contains 1-3% nicotine and that waste containing less than 2% nicotine can also be utilized. A process developed by the National Chemical Laboratory, Poona, reportedly enables recovery of about 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 produced from waste tobacco and liquors obtained during the manufacture of chewing and smoking tobacco. The reported process involves maceration of tobacco waste with water and lime, steam distillation, neutralization of the distillate with sulphuric acid, and concentration. The product has applications as an insecticide against various agricultural pests and has also been described in the report as a starting material for producing purified nicotine and nicotine derivatives.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 900 Kg./Day |
| Land & Building (8000 sq.mt.) | Rs. 2.47 Cr |
| Plant & Machinery | Rs. 1.44 Cr |
| Working Capital for 1 Month | Rs. 6.74 Cr |
| Total Capital Investment | Rs. 10.85 Cr |
| Rate of Return | 63% |
| Break Even Point | 31% |
Content Index
- INTRODUCTION
- USES AND ADVANTAGE OF NICOTINE SULPHATE
- CHEMICAL COMPOSITION:
- MODE OF ACTION:
- USES:
- SPECIAL FEATURES:
- ADVANTAGES:
- PROPERTIES OF NICOTINE SULPHATE
- HAZARD AND SHIPPING REGULATION:-
- PHYSIOLOGY & TECHNOLOGY OF NICOTINE
- NICOTINE COMPOUND
- NICOTINE SULPHATE 40% SOLUTION
- 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
- SEDIMENTATION TEST
- B-1 PROCEDURE
- B-2 REPORT
- COMPOSITION AND APPLICATION NICOTINE SULPHATE 40% SOLUTION
- CHEMICAL COMPOSITION:
- MODE OF ACTION:
- USES:
- CHEMICAL FORMULA:
- ADVANTAGES:
- NICOTINE SULPHATE 40%
- MARKET OVERVIEW OF NICOTINE SULPHATE
- THIS IS BECAUSE OF TWO MAIN REASONS
- 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:
- SOME OF THE IMPORTANT PATENTED PROCESS INCLUDES:
- RECOMMENDATIONS:
- OVERVIEW OF NICOTINE MARKET
- PRESENT MANUFACTURERS/SUPPLIERS OF NICOTINE SULPHATE
- EXPORTER OF NICOTINE BASED PRODUCTS
- TOBACCO WASTE SOURCE AND AVAILABILITY
- SOURCES:
- AVAILABILITY OF TOBACCO WASTE:
- PRESENT UTILIZATION OF TOBACCO WASTE:
- 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 NECOTINESULPHATE
- 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%)
- PROCESS DESCRIPTION AND MATERIAL BALANCE OF NICOTINE SULPHATE 40%
- OVERALL MATERIAL BALANCE
- MANUFACTURING PROCESS OF NICOTINE SULPHATE 99% PURITY
- VACUUM DISTILLATION WORKING PRINCIPLE
- VACUUM DISTILLATION COLUMN
- VACUUM IN REACTOR
- ADVANTAGE OF VDU
- PROCESS FLOW DIAGRAM
- MANUFACTURING PROCESS OF NICOTINE (USP)
- PROCESS FLOW DIAGRAM
- NICOTINE EXTRACTION FROM TOBACCO LEAVES
- 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) DIRECT REMOVAL FROM THE RAW MATERIAL STEAM:-
- III. DESTRUCTIVE DISTILLATION
- RECOVERY OF SOLVENT
- IMPLEMENTATION SCHEDULE:-
- OPTIMIZATION OF NICOTINE SUPPHATE
- 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
- HAZARDOUS FACT SHEET FOR NICOTINE SULPHATE
- HAZARD SUMMARY
- IDENTIFICATION
- REASON FOR CITATION
- HOW TO DETERMINE IF YOU ARE BEING EXPOSED
- WORKPLACE EXPOSURE LIMITS
- WAYS OF REDUCING EXPOSURE
- HEALTH HAZARD INFORMATION
- ACUTE HEALTH EFFECTS
- CHRONIC HEALTH EFFECTS
- CANCER HAZARD
- REPRODUCTIVE HAZARD
- OTHER LONG TERM EFFECTS
- MEDICAL
- MEDICAL TESTING
- EKG
- CONDITIONS MADE WORSE BY EXPOSURE
- WORKPLACE CONTROLS AND PRACTICES
- PERSONAL PROTECTIVE EQUIPMENT
- CLOTHING
- EYE PROTECTION
- RESPLRATORY PROTECTION
- IMPROPER USE OF RESPIRATORS IS DANGEROUS.
- MATERIAL SAFETY DATA SHEET NICOTINE SULPHATE 40%
- CHEMICAL IDENTIFICATION
- PHYSICAL IDENTIFICATION
- HAZARDS IDENTIFICATION
- TOXICITY DATA
- STABILITY
- PREVENTIVE STEPS
- FIRST AID MEASURES
- STORAGE & HANDLING
- CONSULTANT AND TECHNOLOGY SUPPLIERS
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF TOBACCO WASTE
- SUPPLIERS OF BENZENE
- SUPPLIERS OF LIME POWDER
- SUPPLIERS OF PLANT AND 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 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 is a salt formed by combining nicotine with sulphuric acid and is used in the report primarily as an agricultural insecticide. It can be produced by extracting nicotine from tobacco waste and converting the recovered nicotine into its sulphate form. The report describes nicotine sulphate as a brown liquid and discusses its use against several insect pests. Because nicotine is biologically active and potentially hazardous, industrial production, handling, storage, and application require appropriate safety controls and compliance with applicable regulations.
Nicotine sulphate can be manufactured from tobacco waste through extraction, steam distillation, acid neutralization, and concentration. In the process described in the report, tobacco waste is macerated with water and lime before steam distillation is used to recover nicotine-containing distillate. The distillate is then neutralized with sulphuric acid and concentrated to produce nicotine sulphate. Industrial implementations may incorporate additional filtration, separation, purification, testing, and packing stages depending on the desired product specification and process configuration.
Tobacco processing residues such as rejected leaves, broken lamina, midribs, stalks, and stems can be considered sources for nicotine recovery. The report states that Indian tobacco waste generally contains 1-3% nicotine and indicates that waste with less than 2% nicotine can also be utilized. The suitability of a particular waste stream depends on its nicotine concentration, moisture content, contaminants, physical form, availability, and economics. Representative sampling and laboratory analysis are therefore important when evaluating a raw-material source for an industrial extraction process.
Nicotine sulphate has historically been used as an insecticide for controlling various agricultural and livestock pests. The report identifies aphids, whiteflies, leafhoppers, thrips, mites, lice, ticks, and other pests among its reported applications. It describes activity through contact and fumigation mechanisms and discusses applications on fruit, vegetables, crops, flowers, and livestock ectoparasites. Its use today must be evaluated against applicable pesticide registrations, occupational safety requirements, environmental rules, and restrictions in the intended market.
Tobacco waste can be a useful industrial raw material because it contains recoverable nicotine and other potentially valuable constituents. Instead of treating rejected leaves, broken tobacco material, stalks, stems, and midribs solely as waste, an appropriately designed process can recover selected compounds for further use. The report specifically identifies nicotine, nicotine sulphate, tobacco seeds, rutin, pectic substances, and certain organic acids as potential products or constituents. Commercial feasibility depends on raw-material availability, extraction efficiency, product specifications, processing costs, safety requirements, and market demand.
Equipment requirements depend on the selected extraction and purification route, but the report identifies several process units associated with nicotine sulphate production. These include steam distillation kettles, nicotine concentration chambers, concentration flasks, reaction vessels, industrial filters, distillation units, evaporators, digesters, centrifuges, storage tanks, boilers, water treatment equipment, and packing equipment. A detailed equipment list should ultimately be established from the process flow diagram, material balance, product specification, utilities requirement, hazardous-area assessment, and applicable engineering and safety standards.
Nicotine sulphate manufacturing requires controlled handling of nicotine-containing materials and the chemicals used during extraction and processing. The report includes dedicated sections covering hazards, exposure, workplace controls, personal protective equipment, first aid, storage, and handling. Industrial facilities should use appropriate containment, ventilation, chemical-resistant equipment, exposure controls, emergency procedures, and worker training. Hazard assessments and safety data should be reviewed for each chemical used, including tobacco-derived nicotine, lime, sulphuric acid, and any solvents involved in the selected process, before plant operation.
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