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 valuable by-products, particularly nicotine and tobacco seeds. Tobacco waste can also serve as a source of nicotine acid, nicotine sulphate, rutin, pectic substances, and certain organic acids.
Indian tobacco waste typically 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, can recover about 95% of the nicotine present in tobacco waste as nicotine sulphate. The report notes its commercial exploitation by Tobacco By Products Ltd., Guntur, and identifies Urvakunj Tobacco By Products, Dharmaj, Gujarat, as another nicotine sulphate manufacturing unit.
Nicotine sulphate is produced from waste tobacco and liquors obtained from chewing and smoking tobacco factories. The reported process involves macerating tobacco waste with water and lime, steam distillation, neutralization of the distillate with sulphuric acid, and concentration. Nicotine sulphate is used as a plant-origin insecticide against various agricultural pests and is also relevant to nicotine recovery and downstream applications.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 2 MT/Day |
| Land & Building (20,000 sq.mt.) | Rs. 14.54 Cr |
| Plant & Machinery | Rs. 1.72 Cr |
| Working Capital for 1 Month | Rs. 7.66 Cr |
| Total Capital Investment | Rs. 24.19 Cr |
| Rate of Return | 35% |
| Break Even Point | 38% |
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
- COMPOSITION AND APPLICATION NICOTINE SULPHATE 40% SOLUTION
- CHEMICAL COMPOSITION:
- MODE OF ACTION:
- USES:
- CHEMICAL FORMULA:
- ADVANTAGES:
- NICOTINE SULPHATE 40%
- MARKET OVERVIEW OF NICOTINE SULPHATE
- 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:
- PRESENT MANUFACTURERS/SUPPLIERS OF NICOTINE SULPHATE
- 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
- 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
- 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 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 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 is a salt of nicotine and sulphuric acid that can be recovered from tobacco and tobacco waste.
The report describes it as a plant-origin insecticide used against several agricultural pests and certain ectoparasites affecting livestock. It is produced by extracting nicotine from tobacco material and converting the recovered nicotine into its sulphate form. The report also identifies nicotine sulphate as a starting material for the manufacture of purified nicotine complying with USP and EP pharmacopeias.
Nicotine sulphate can be manufactured from tobacco waste through extraction, steam distillation, acid neutralization, and concentration.
In the process described in the report, waste tobacco is macerated with water and lime and subsequently subjected to steam distillation. The nicotine-containing distillate is neutralized with sulphuric acid and concentrated to obtain nicotine sulphate. The report also discusses alternative extraction routes, purification, testing, packing, and process optimization for nicotine and nicotine sulphate products.
Nicotine recovery can use several tobacco-processing residues, including rejected leaves, broken lamina, midribs, stalks, and stems.
These materials accumulate during tobacco harvesting and manufacturing and can retain useful quantities of nicotine. The report states that Indian tobacco waste commonly contains about 1-3% nicotine and that material containing even less than 2% nicotine can be utilized. Suitability for a particular process depends on the composition and condition of the available waste and the extraction technology selected.
Nicotine sulphate is primarily described in the report as an insecticide for controlling a range of agricultural pests.
Its reported applications include control of aphids, white flies, leafhoppers, thrips, mites, bugs, worms, snails, slugs, and other pests. The report also mentions applications against lice, mites, and ticks affecting livestock. In addition, nicotine sulphate is identified as a starting material for producing purified nicotine that can be used in downstream nicotine salts and complexes.
Nicotine sulphate acts on the central nervous system of insects and has both contact and fumigation action.
According to the report, it is classed as a contact insecticide but can also act principally as a fumigant and, in some circumstances, as a stomach poison. Its effectiveness is described particularly against soft-bodied and small insects. The mode of action and application method are important considerations when assessing product performance, handling requirements, and appropriate use in agricultural settings.
Nicotine Sulphate 40% is reported to contain 40% nicotine alkaloid by weight, along with vegetable oils, tar, water, and other ingredients.
The report specifies 400gm/1000gm as nicotine alkaloid, equivalent to 40%(w/w), 20gm /1000gm as vegetable oils, tar, etc., equivalent to 2% (w/w), and 580gm/1000gm as water and other ingredients, equivalent to 58% (w/w). These values are reproduced from the supplied project report and should be considered in conjunction with applicable product specifications and regulatory requirements.
The supplied project report specifies a plant capacity of 2 MT/Day and a total capital investment of Rs. 24.19 Cr.
The stated cost estimation includes Land & Building (20,000 sq.mt.) at Rs. 14.54 Cr, Plant & Machinery at Rs. 1.72 Cr, and Working Capital for 1 Month at Rs. 7.66 Cr. The report also gives a Rate of Return of 35% and a Break Even Point of 38%. These figures are reproduced exactly as provided and have not been recalculated or independently validated.
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