• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    Fertilizer Composition and Method for its Preparation The present invention relates to a method of producing a granulated and compacted fertilizer having incorporated micronutrients, where the granulated primary nutrient and micronutrients are blended into smaller particle sizes before being compacted into particle sizes. larger particles for easier handling.
    公开号:BR112015022248B1
    申请号:R112015022248-0
    申请日:2014-03-14
    公开日:2022-01-11
    发明作者:Lawrence Alan Peacock；Dan M. Froelich
    申请人:The Mosaic Company；
    IPC主号:
    专利说明:

    PRIORITY CLAIM
    [001] This application claims priority to U.S. Interim Application Serial No. 61/782,377, filed March 14, 2013, and titled FERTILIZER COMPOSITION AND METHOD FOR PREPARING THE SAME,” which is incorporated by reference in its entirety. FIELD OF THE INVENTION
    [002] The present invention is directed to a granulated fertilizer that presents micronutrients. Specifically, the present invention is directed to a compacted granulated fertilizer and an associated process for forming such a fertilizer. BACKGROUND OF THE INVENTION
    [003] Many chemical elements, including both mineral and non-mineral elements, are important for the growth and survival of a plant. Non-mineral elements can include, for example, hydrogen, oxygen and carbon, generally available in air and water. Mineral nutrients including nitrogen, phosphorus, and potassium are available or become available in the soil for uptake by plant roots.
    [004] Mineral nutrients can be divided into two groups: macronutrients, including primary and secondary nutrients, and micronutrients. Primary mineral nutrients include nitrogen (N), phosphorus (P) and potassium (K). Large amounts of these nutrients are essential for plant survival, and therefore make up most of the fertilizer composition. In addition to primary nutrients, secondary nutrients are needed in much smaller amounts than primary nutrients. Secondary nutrients may include, for example, calcium (Ca), sulfur (S), and magnesium (Mg). Micronutrients can include, for example, boron (B), copper (Cu), iron (Fc), manganese (Mn), molybdenum (Mo), zinc (Zn), chlorine (Cl), cobalt (Co), sodium ( Na) and their combinations.
    [005] Regarding micronutrients, their sources vary considerably in terms of their physical state, chemical reactivity, cost and availability to plants. The most common method of utilizing micronutrients in crops is soil application. Recommended application rates are generally less than 10 lb/acre (0.001121 kg/m2) on an elemental basis, so uniform application of micronutrient sources separately in the field can be difficult. The inclusion of micronutrients with a fertilizer mix is a suitable application method and allows for more uniform distribution with conventional application equipment. Costs are also reduced by eliminating a separate application step. Four methods of applying micronutrients with fertilizer mixes can include incorporation during production, mass mixing with granular fertilizers, coating in granular fertilizers, and mixing with fluid fertilizers.
    [006] Incorporation during production is the use of one or more micronutrients directly into fertilizer granules, such as NPK, potash or phosphate fertilizers, as they are produced. This practice allows each fertilizer granule to present a coherent concentration of the desired micronutrient(s) and an even distribution of the micronutrient(s) throughout the granular fertilizers. Because the granules are evenly dispersed over the growing area, the micronutrient(s) are suitable.
    [007] Mixing the mass with granular fertilizers consists of separately mixing secondary nutrients with granulates and/or micronutrient compounds with granular fertilizers, such as phosphate or potash. The main advantage of this practice is that fertilizer grades can be produced by providing recommended micronutrient rates for a given field with common fertilizer application rates. The main disadvantage is that nutrient separation can occur during the mixing operation and with subsequent handling. To reduce or avoid size separation during handling and transport, micronutrient granules should be very close in size to phosphate and potash granules. Because these micronutrients are needed in very small amounts for plant nutrition, this practice results in the distribution of micronutrient granules unevenly and generally farther away from most plants to provide an immediate benefit as they migrate into the soil solution only few millimeters throughout the growing season.
    [008] The coating of granular fertilizers reduces the possibility of separation. However, some binding materials are unsatisfactory because they do not maintain the micronutrient coatings during bagging, storage and handling, which results in the separation of micronutrient sources from the granular fertilizer components. Steps were taken to reduce the separation problem in the case of secondary nutrients and micronutrients, for example in the case of sulfur or sulfur platelets in the fertilizer portion, as described in US Patent No. 6,544,313 entitled “Sulfur-Containing Fertilizer Composition and Method for Preparing Same”, and in the case of micronutrients, as described in US Patent No. 7,497,891, entitled “Method for Producing a Fertilizer with Micronutrients”, both incorporated herein by reference in their entirety.
    [009] Therefore, there is a need for a fertilizer product that contains one or more micronutrients that maximize the introduction of the micronutrient(s) into the soil solution and ultimately into the root zone of plants. SUMMARY OF THE INVENTION
    [010] Embodiments of the present invention are directed to a compacted fertilizer composition, and related methods of production, having at least one primary nutrient and at least one additional nutrient that is ground to increase an available reactive surface area, and that are then compacted into granules of the fertilizer composition.
    [011] In one embodiment of the present invention, a fertilizer base composition containing at least one primary nutrient is separately formulated and size separated to identify undersized granules that are unsuitable for use in conventional fertilizer products. At least one additional nutrient, eg a secondary nutrient, a micronutrient or a micronutrient complex may be added and mixed into undersized granules. The mixture of these granules and at least one additional nutrient can then be ground to increase the available reactive surface area of the primary nutrient and at least one additional nutrient. The crushed mixture can then be compacted to form a compacted fertilizer granule having the primary nutrient and at least one additional nutrient. The crushed mixture can then be compacted to form a compacted fertilizer granule containing the primary nutrient and at least one additional nutrient. As the compacted fertilizer granule is broken down, the available surface area of the crushed primary nutrient and at least one additional nutrient allows maximum introduction and reaction in the root zone.
    [012] By pre-mixing the fertilizer granules with at least one additional nutrient, and at least one additional nutrient can be evenly distributed through the undersized granules to provide the correct concentration or ration of the primary nutrients for additional nutrients in the mix. As a result, the concentration of primary and additional nutrients is consistent when compacted fertilizer granules are formed to provide an even distribution over an area in which the granules are distributed. In one aspect, the compacted granules can be adapted to split into constituent granules, granules of primary and additional nutrients in the soil. In this configuration, the compacted fertilizer granules serve as a vehicle to ensure proper distribution of primary and additional nutrients that have been previously ground to maximize reactive surface area.
    [013] A method of producing a fertilizer, according to an embodiment of the present invention, comprises forming an amount of a base fertilizer composition including at least one primary nutrient. In a particular embodiment, the base fertilizer composition comprises a phosphate fertilizer, such as, for example, monoammonium phosphate (MAP) or diammonium phosphate (DAP), with the primary nutrient being phosphorus.
    [014] The method also comprises granulating the amount of the base fertilizer composition into a plurality of fertilizer granules which can be separated by size into appropriately sized granules, oversized and undersized granules. In one aspect, the method comprises adding and mixing the dough with at least one additional nutrient, such as, for example, a secondary nutrient or an additional micronutrient or micronutrient complex for undersized granules to form a fertilizer mixture. The method also comprises grinding the fertilizer mixture to form a comminuted mixture having the primary nutrient and at least one additional nutrient. Finally, the method may also comprise compacting the crushed fertilizer mixture to form a plurality of compacted fertilizer granules with the main nutrient and at least one additional nutrient.
    [015] The summary of the various representative embodiments of the invention is not intended to describe each illustrated embodiment or each embodiment of the invention. The embodiments are chosen and described so that others of skill in the art can consider and understand the principles and practices of the invention. The figures in the detailed description below exemplify these modalities. BRIEF DESCRIPTION OF THE FIGURES
    [016] The invention can be fully understood according to the description below of the various embodiments of the invention according to the figures, where: Figure 1 shows a flow diagram of a method of producing granulated fertilizer according to an embodiment of the invention.
    [017] Although the invention is subject to various modifications and alternatives, its specific forms have been demonstrated as an example in the figure and will be described in detail. However, it should be understood that the intention is not to limit the invention to the described embodiments. Rather, the invention encompasses all modifications, equivalents and alternatives within the spirit and scope of the invention as defined by the appended claims. DETAILED DESCRIPTION OF THE INVENTION
    [018] As shown in Figure 1, a method for producing a quantity of compacted fertilizer granules, according to an embodiment of the present invention, generally comprises a production stage 10, a size separation/correction stage 12, a mixing stage 14 and a compaction stage 16.
    [019] As shown in figure 1, the production stage 10 can also comprise a formulation step 18, a granulation step 20 and a drying step 22. In the formulation step 18, an amount of fertilizer, such as, for example, a phosphate or ammonium phosphate fertilizer is at least partially and chemically produced in a pre-neutralizer and/or reactor. The fertilizer may include, but is not limited to, MAP or DAP, or triple superphosphate fertilizers and combinations thereof.
    [020] In one embodiment, a formulation step 18 comprises a pre-neutralizer which is a stirred reactor that produces an ammonium phosphate slurry. For example, MAP and/or DAP can be produced depending on the rate of ammonium and phosphoric acid fed to the pre-neutralizer.
    [021] In another embodiment of the invention, the formulation step 18 comprises a tubular reactor, such as a cross-flow tubular reactor, which is a reactor where ammonium phosphate is formed by the reaction of ammonia and phosphoric acid. In the pre-neutralizer, MAP and/or DAP can be produced depending on the rate of ammonia and phosphoric acid that is fed to the tubular reactor.
    [022] In another embodiment of the invention, the formulation step 18 comprises a combination of a pre-neutralizer and a tubular reactor, where a portion of the ammonium phosphate fertilizer is formed in the pre-neutralizer, and the other is formed in the tubular reactor , as described in US Patent No. 7,497,891, incorporated herein by reference in its entirety.
    [023] In granulation step 20, the produced fertilizer composition is stirred in a rotating granulation cylinder to form a rolling bed of fertilizer granules. For ammonium phosphate fertilizers, production stage 10 may also comprise a spraying step 24, where fertilizer granules are treated in an under-bed ammonia spray to complete the ammonium phosphate reaction. In drying step 22, the fertilizer granules are dried to reduce the moisture content and to remove unreacted volatiles.
    [024] As shown in Figure 1, the size correction/separation stage 12 may also comprise a sizing step where the granulated fertilizer is separated into a plurality of streams according to particle size. In a product sizing step 26, quantities of fertilizer granules are passed through a plurality of sieves to separate the granules into a suitably sized granule stream 28, an undersized granule stream 30, and a oversized granule stream 21. Correct sized stream 28 comprises fertilizer granules having particle sizes from about 2 mm to about 4 mm in diameter. The undersized granule stream 30 comprises fertilizer granules having particle sizes smaller than about 2 mm in diameter. The oversized granule stream 32 comprises fertilizer granules having particle sizes greater than about 4 mm in diameter. The larger granule stream 32 may be subjected to a milling step 34 to form a milled recycle stream 35, where the particle size of this stream is about 4 mm in diameter. The shredded recycled stream 35 and a portion of the undersized grain stream 34 can be recycled to the granulation stage 20 as the remainder and provide a building block for granule formation.
    [025] In the mixing step 14, one or more additional nutrient streams, such as, for example, a micronutrient stream 36 with one or more micronutrients or micronutrient complexes and/or a secondary nutrient stream 38, which has a or more nutrients, are combined with the remaining portion of the oversized granule stream 30 that has not been recycled to the granulation step 20. The micronutrient stream 36 and/or the secondary nutrient stream 38 are mixed to a of undersized granules to form a 40 fertilizer mix, where additional nutrients are evenly distributed throughout the 40 fertilizer mix.
    [026] A concentration of each micronutrient in the fertilizer mix can be from about 0.1 to about 3% by weight. The micronutrient stream 36 may comprise at least one micronutrient including, but not limited to, boron, copper, iron, manganese, molybdenum, zinc and combinations thereof. In one aspect, the micronutrients in the micronutrient stream 36 may have a particle size of from about 50 to about 150 µm, and more particularly from about 75 µm to about 100 µm with the resulting fertilizer mixture 40 being generally homogeneous. .
    [027] The secondary nutrient stream 38 may include, but is not limited to, ammonium sulfate, calcium sulfates, elemental sulfur and combinations thereof. In one embodiment, the secondary nutrients in the secondary nutrient stream 38 may have a particle size of from about 50 to about 150 µm, and more particularly from about 75 µm to about 100 µm, such that the resulting fertilizer mixture 40 is generally homogeneous.
    [028] The size correction/separation stage 12 may also include a comminution step for mixing the fertilizer 40 to form a mixture of the comminuted fertilizer 42 with particles of the mixture having a size of about 50 to about 150 μm and more particularly from about 50 μm to about 100 m, which are similar in size to additional nutrients such as, for example, micronutrients and/or secondary nutrients in the micronutrient stream 38 to promote effective upstream compaction as well as homogeneity of the final compacted product.
    [029] In an alternative embodiment, a secondary nutrient may be added during production stage 10 and prior to the addition of micronutrients. For example, liquefied sulfur can be applied or sprayed into the fertilizer base composition in the granulator, as described in US Patent No. 6,544,313 entitled "Sulfur-Containing Fertilizer Composition and Method for Preparing Same", incorporated herein by reference in its entirety. Alternately, if the secondary nutrient is added as a separate component after granulating and/or sizing the fertilizer base composition in this configuration, the mixing step 14 may also comprise a milling step where the stream of undersized granules normal 30 and a secondary nutrient mixture, are ground or pulverized, and mixed into a homogeneous mixture of primary and secondary nutrient particles before being combined with the micronutrient stream 36.
    [030] In compaction stage 16, the crushed fertilizer mixture 42 is compacted into larger granules that can be readily transported and handled. Optionally, one or more binding agents or components may be added to the crushed fertilizer mixture 42 to improve strength or handling ability of a finished compacted fertilizer granule 44 or granular MOP product so that the compacted fertilizer granules 46 are likely not to erode or break during handling or transportation, as described in US Patent No. 7,727,501, entitled “Compacted granular potassium chloride, and method and apparatus for production of the same”, incorporated herein by reference in its entirety. The binding agent is a chemical that is added to the compaction circuit feed to improve the strength and quality of the compacted particles. The binding agent acts as a scavenger or chelator of impurities in the fertilizer composition, while providing adhesive properties to the compacted mixture. Binding agents may include, for example, sodium hexametaphosphate (SHMP), tetrasodium pyrophosphate (TSPP), tetrasodium pyrophosphate (TKPP), sodium tripolyphosphate (STPP), potassium silicate, sodium silicate, starch, dextran, lignosulfonate, bentonite, montmorillonite, kaolin, or combinations thereof. In addition, some micronutrients can act as binding agents to improve particle strength.
    [031] The compaction process can be carried out using conventional equipment, such as a roller compactor or similar. The produced intermediate can then be further processed to obtain the final desired granular product using methods such as grinding, sorting or other conventional grading methods suitable to produce a finished product of the proper particle size or type, as discussed above.
    [032] After the compaction process, the compacted fertilizer granule 44 may have a particle size diameter of about 2 mm to about 4 mm. In one aspect, the compacted fertilizer granules 46 are adapted to break up in the soil into granules of primary nutrient, secondary nutrient and/or micronutrients to increase the surface area for interaction with plant roots.
    [033] Although the invention is subject to various modifications and alternative forms, its specific aspects have been demonstrated through the figures and are described in detail. It is understood, however, that the intention is not to limit the invention to the particular embodiments described, but rather to encompass all modifications, equivalents, and alternatives that are within the spirit and scope of the invention, as defined by the appended claims.
    权利要求:
    Claims (10)
    [0001]
    1. Process for forming a compacted phosphate fertilizer granule, CHARACTERIZED in that it comprises: the production of an ammonium phosphate slurry; the granulation of the slurry to produce phosphate fertilizer granules; the classification of fertilizer granules by size into granules of suitable sizes having a diameter of 2 mm to 4 mm, oversize having a diameter greater than 4 mm and undersize having a diameter less than 2 mm; the addition of at least one additional nutrient to the sized granules undersized; grinding the undersized granules to form a stream of crushed granules; and compacting the stream of ground granule to form a granule of the compacted phosphate fertilizer having a diameter of 2 mm to 4 mm.
    [0002]
    2. Process according to claim 1, CHARACTERIZED in that at least one additional nutrient is selected from the group consisting of secondary nutrients, micronutrients and combinations thereof.
    [0003]
    3. Process according to claim 2, CHARACTERIZED in that the at least one additional nutrient comprises one or more secondary nutrients selected from the group consisting of: ammonium sulfate, calcium sulfate, elemental sulfur and combinations thereof.
    [0004]
    4. Process according to claim 2, CHARACTERIZED in that the at least one additional nutrient comprises one or more micronutrients selected from the group consisting of boron, copper, iron, manganese, molybdenum, zinc, their complexes and combinations thereof.
    [0005]
    5. Process according to claim 2, CHARACTERIZED by the fact that at least one additional nutrient has a particle size diameter of 50 μm to 150 μm.
    [0006]
    6. Process according to claim 1, CHARACTERIZED in that the step of compacting the crushed granule stream also comprises: adding a binding agent to the fertilizer mixture of the crushed granule stream to improve the adhesion of the compacted fertilizer granule.
    [0007]
    7. Process, according to claim 1, CHARACTERIZED by the fact that it also comprises: the crushing of granules with an above-normal size; and recycling the over-sized crushed granules to the granulation step.
    [0008]
    8. Process, according to claim 7, CHARACTERIZED in that it also comprises recycling a portion of the undersized granules to the granulation step.
    [0009]
    9. Process, according to claim 1, CHARACTERIZED in that the slurry granulation step also comprises: introducing the slurry into a rotating granulation cylinder to form a rolling bed of fertilizer granules; and spraying the rolling bed of fertilizer granules with ammonia.
    [0010]
    10. Process according to claim 1, CHARACTERIZED in that the phosphate fertilizer granules comprise a monoammonium phosphate (MAP), diammonium phosphate (DAP), or a combination thereof.
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    法律状态:
    2018-02-27| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-10-29| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2021-07-06| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|
    2021-11-03| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2022-01-11| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 14/03/2014, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US201361782377P| true| 2013-03-14|2013-03-14|
    US61/782,377|2013-03-14|
    PCT/US2014/028565|WO2014152994A1|2013-03-14|2014-03-14|Fertilizer composition and method for preparing the same|
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