Fertilizer composition containing carbon-based additive and preparation method thereof

Abstract

The present invention relates to a fertilizer composition containing a carbon-based additive, the fertilizer composition being a macronutrient or mineral fertilizer product comprising a plurality of fertilizer granules, each containing a fertilizer carrier, such as an N / P / K fertilizer, for introducing a carbon-based additive for enhancing the mass of the granules, and a process for preparing the same. The carbon-based additive may have a functionalized or activated surface, such as a carbon black acid having a carboxyl group on the surface. The functionalized surface can react with the nutrients or both in the soil environment in which it is dispersed, thereby enhancing the absorption capacity of the plant nutrients. In one example, the carbon-based additive is a dry additive, such as powdered or particulate carbon black acid, incorporated into a fertilizer carrier composition.

Description

[0001] Related applications

[0002] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 657,576, filed June 7, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates generally to fertilizers, and more specifically to a fertilizer product containing carbon-based additives (such as carbon black acid). Background Technology

[0004] Fertilizers are used to deliver nutrients to plants and the surrounding soil to grow healthier, stronger crops. Fertilizers typically include macronutrients such as potassium, phosphorus, and nitrogen, or combinations thereof (“N / P / K”). For example, potassium fertilizers (or potassium salts) can be used to provide potassium to plants when the soil cannot provide the optimal amount. Potassium salts are a general term used to describe a variety of potassium-containing agricultural fertilizers. Fertilizers can be spread on the soil surface before tilling and planting crops, and can also be added later in the plant's growth period as needed by the crop. The potassium then dissolves into the soil, promoting plant growth by providing the necessary nutrients to the plant.

[0005] Fertilizers are typically produced by a number of well-known methods, including but not limited to granulation and compaction. For example, wet granulation is a process in which a fertilizer composition (such as a slurry containing a phosphate material) enters a drum (such as a drum granulator), in which the slurry is rolled and solidified, and then granulated into fertilizer pellets. Optionally, other additives (such as minor or micronutrients) may be added in the drum during slurry formation and / or during pellet formation. Furthermore, as in the example of a phosphate composition containing ammonium phosphate, ammonia may be added to the drum (e.g., by bubbling) to control the ammonia / phosphate ratio. An example of a granulation process is described, for example, in U.S. Patent 6,544,313, the entire contents of which are incorporated herein by reference.

[0006] Compaction is a process that can be used to manufacture fertilizer granules from fine, dry powder particles. Fertilizer compaction typically involves subjecting fine, dry powder particles to a high-pressure environment (such as high-pressure rollers), causing the fine particles to be compressed into flakes or sheets. The flakes or sheets are then broken down into smaller particles of the desired size. An example of a compaction process for forming potash fertilizer is described, for example, in U.S. Patent 7,727,501, the entire contents of which are incorporated herein by reference. Fertilizers can improve plant health by providing nutrients to plants, but other benefits may be required.

[0007] Fertilizers that enhance crop yield response may be beneficial. Furthermore, in some cases, it may be desirable to minimize fertilizer use. Reducing fertilizer use can lower operating costs, among other reasons. Therefore, fertilizers that improve nutrient use efficiency will be advantageous, as this can result in the same nutrient delivery but require less fertilizer. Additionally, in some geographic areas, severe weather is becoming increasingly common and may expose plants to high stress environments caused by drought, high temperatures, storms, or nutrient deficiencies. Fertilizers that enable plants to better cope with and mitigate these high stress environments will be further advantageous. Moreover, soil health may deteriorate due to geographic location or over-harvesting. Fertilizer granules that improve soil health and promote microbial activity in the local soil area surrounding the granule will be advantageous. Better granule quality indicators to reduce or minimize granule degradation and dust generation during storage, transportation, and handling can help achieve these goals. Summary of the Invention

[0008] This disclosure generally describes a macronutrient or mineral fertilizer product comprising a plurality of fertilizer granules, each granule comprising a fertilizer carrier (such as an N / P / K fertilizer) incorporating a carbon-based additive to enhance granule mass. The carbon-based additive may have a functionalized or activated surface (i.e., a surface containing active or functional groups), for example, carbon black acid with hydroxyl or carboxyl groups on its surface. The functional groups may react with macronutrients, minor nutrients, and / or micronutrients of the base carrier composition, with nutrients in the soil environment in which the carbon-based additive is dispersed, or both, to enhance the plant's ability to absorb nutrients. In an alternative embodiment, the carbon-based additive does not include a functionalized or activated surface, such as, but not limited to, biochar, starch, carbon black, humic substances, fulvic acid, etc., or combinations thereof. In yet another embodiment, the carbon-based additive comprises a combination of additives having functionalized or activated surfaces and additives not having functionalized or activated surfaces.

[0009] In a non-limiting example, the carbon-based additive is a dry additive, such as powder or granules of carbon black acid, or other carbon-based additives. In embodiments, the particle size of the carbon-based additive is, for example, but not limited to, in the range of about 120 nanometers (nm) to about 500 micrometers (μm). In alternative embodiments, the carbon-based additive is in liquid form, such as syrup. In other embodiments, the carbon-based additive is a combination of liquid and powder forms, such as a dry powder form incorporated into and / or coated onto a fertilizer carrier, and a liquid form incorporated into and / or coated onto a fertilizer carrier.

[0010] The fertilizer carrier may include, for example, potassium-containing or potassium salt fertilizers, such as, but not limited to, potassium chloride (KCl), potassium chloride (MOP), potassium sulfate (MOP), potassium magnesium sulfate (MOP), potassium nitrate, potassium hydroxide, anhydrous potassium magnesium sulfate (MgSO4), polyhalite (K2Ca2Mg(SO4)4·2H2O), etc., and phosphate fertilizers such as, but not limited to, monoammonium phosphate (MAP), sulfur-fortified MAP (e.g., The fertilizers include, but are not limited to, diammonium phosphate (DAP), mono-superphosphate, triple-superphosphate, struvite, etc., nitrogen fertilizers such as, but not limited to, urea, nitrates or combinations thereof, or other macronutrients such as, but not limited to, magnesium sulfate, or any combination thereof. The fertilizers may also include various sulfates or combinations thereof, such as calcium sulfate, magnesium sulfate, and ammonium sulfate; minor nutrients include calcium, magnesium, and sulfur (as elemental sulfur and / or sulfur in sulfate form); and / or micronutrients include zinc, manganese, iron, copper, molybdenum, boron, chlorine, cobalt, and sodium.

[0011] The carbon-based additive may be present in an amount of about 0.01–5% by weight of the total fertilizer granules, or more specifically, about 0.05–1% by weight of the fertilizer granules. The carbon-based additive, whether in solid or liquid form, may be incorporated into the fertilizer granules themselves, coated thereon, or a combination of both.

[0012] The fertilizer granules can be manufactured by any conventional means, including wet granulation, dry granulation, compaction, chemical production, or any suitable method known to those skilled in the art. The carbon-based additive can be incorporated into the process flow at any point, such as in a rotary granulation drum, in the formation of the fertilizer composition slurry, or in the compaction process with fine granules, depending on the production method. The incorporation rate of the carbon-based additive can vary between about 0.01% by weight and 5% by weight, or more specifically, about 0.05% to 1% of the fertilizer. Fertilizers containing carbon-based additives can offer several benefits when used in crop cultivation, including enhanced yield response, enhanced nutrient use efficiency, improved stress mitigation response, improved soil health, and / or triggered microbial activity.

[0013] In some non-limiting examples, the potash fertilizer is co-compacted with a carbon-based additive and may contain white potash fertilizer and / or red potash fertilizer. Furthermore, in some embodiments, the carbon-based additive may be incorporated at a rate of 0.1% to 1% of the potash fertilizer. Even further, in some embodiments, the carbon-based additive may include various percentages of pre-loaded micronutrients.

[0014] The above description is not intended to depict every example or embodiment of the present disclosure. The following figures and detailed description illustrate these examples in more detail. Attached Figure Description

[0015] A more comprehensive understanding of the subject matter of this article can be achieved by considering the following detailed descriptions of various examples in conjunction with the accompanying drawings, in which:

[0016] Figure 1 A powdered carbon-based additive (carbon black acid) without pre-loaded micronutrients is shown.

[0017] Figure 2 White potassium fertilizer and compacted white potassium fertilizer with carbon-based additives without pre-loaded micronutrients at an incorporation rate of 0.1% to 1% are shown.

[0018] Figure 3 Red potassium fertilizer compacted with a carbon-based additive containing 0.05% of pre-loaded micronutrients is shown.

[0019] Figure 4 Red potassium fertilizer compacted with a carbon-based additive containing 0.25% of pre-loaded micronutrients is shown.

[0020] Figure 5 Red potassium fertilizer compacted with a carbon-based additive containing no pre-loaded micronutrients at an incorporation rate of 0.1% is shown.

[0021] Figure 6 Red potassium fertilizer compacted with a carbon-based additive containing 0.5% of pre-loaded micronutrients is shown.

[0022] While various modifications and alternatives may be made to the various examples, their specific details have been shown by way of examples in the accompanying drawings and will be described in detail. However, it should be understood that the purpose is not to limit the claimed invention to the specific examples described. Rather, the purpose is to cover all modifications, equivalents, and alternatives that fall within the spirit and scope of this disclosure. Detailed Implementation

[0023] Before turning to the accompanying drawings, which illustrate certain examples in detail, it should be understood that this disclosure is not limited to the details or methods set forth in the specification, nor to what is shown in the drawings. It should also be understood that the terminology used herein is for descriptive purposes only and should not be considered limiting.

[0024] Figure 1A powdered carbon-based additive with a functionalized surface is shown, more specifically, carbon black acid. As previously described, the carbon-based additive may have a functionalized or activated surface (i.e., the surface contains active or functional groups, such as carboxyl and / or hydroxyl groups). These functional groups may react with macronutrients, minor nutrients, and / or micronutrients of the base carrier composition, with nutrients in the soil environment in which the carbon-based additive is dispersed, or both, to enhance the plant's ability to absorb nutrients, thereby enhancing yield response, enhancing nutrient use efficiency, improving stress relief response, improving soil health, triggering microbial activity, or any combination thereof.

[0025] Examples of carbon-based additives include carbon black acid derived from the incomplete combustion of materials comprising plant matter or other organic matter or petroleum products, which is oxidized by controlled chemical oxidation to generate functional groups on its surface. In one non-limiting embodiment, the carbon-based additive comprises carbon black acid having carboxyl groups on its surface.

[0026] In an alternative embodiment (not shown), the carbon-based additive does not include functionalized or activated surfaces, such as, but not limited to, biochar, starch, carbon black, humic substances, fulvic acid, etc., or combinations thereof. In other embodiments, the carbon-based additive comprises a combination of additives having functionalized or activated surfaces and additives not having functionalized or activated surfaces.

[0027] In a non-limiting example, the carbon-based additive is a dry additive, such as a powder or granules of carbon black acid. The particle size of the carbon-based additive is, for example, but not limited to, the range from about 120 nanometers (nm) to about 500 micrometers (μm), more specifically, the range from about 120 nm to about 1 μm, from about 1 μm to about 500 μm, from about 20 μm to about 300 μm, or from about 50 μm to about 100 μm. Other sub-ranges within the range of about 120 nanometers (nm) to about 500 micrometers (μm) are also contemplated. In an alternative embodiment, the carbon-based additive is in liquid form, such as syrup. In other embodiments, the carbon-based additive is a combination of liquid and powder forms, such as a dry powder form incorporated into and / or coated onto a fertilizer carrier, and a liquid form incorporated into and / or coated onto a fertilizer carrier.

[0028] The carbon-based additive can be combined with the fertilizer composition described above, which includes: potassium-containing or potassium salt fertilizers, such as, but not limited to, potassium chloride, potassium chloride, potassium sulfate, potassium magnesium sulfate, potassium nitrate, potassium hydroxide, anhydrous potassium magnesium sulfate, polyhalite (K₂Ca₂Mg(SO₄)₄·2H₂O), etc.; phosphate fertilizers, such as, but not limited to, monoammonium phosphate, diammonium phosphate, superphosphate, triple superphosphate, struvite, etc., or any combination thereof, with or without sulfate; minor nutrients and / or micronutrients. The carbon-based additive can be incorporated into granulation, compaction, chemical, electrostatic coating, or any process known to those skilled in the art for the production of fertilizer granules, or combinations thereof (e.g., incorporated into and / or on granules).

[0029] In a non-limiting example, carbon-based additives with functionalized surfaces are mixed with red and / or white potassium fertilizers and compacted to produce, for example, Figures 2 to 6 The co-compacted granules shown are illustrated. Using carbon-based additives with white and / or red potassium fertilizers results in co-compacted potassium fertilizer granules with enhanced capabilities. Co-compacted potassium fertilizer granules with carbon-based additives, among other benefits, enhance crop yield response, improve nutrient use efficiency, improve stress relief response, improve soil health in the localized area surrounding the granules, and trigger microbial activity in the localized area surrounding the granules.

[0030] In some embodiments, the carbon-based additive includes pre-loaded micronutrients. These pre-loaded micronutrients can provide additional benefits to plants and soil, such as further enhancing yield response. The pre-loaded micronutrients may consist of boron, zinc, manganese, or other micronutrients, alone or in combination with each other. Furthermore, the micronutrients may constitute a different percentage of the carbon-based additive.

[0031] exist Figures 2 to 6 In the example shown, the fertilizer with carbon-based additives includes co-compacted potassium fertilizer granules. To prepare the co-compacted potassium fertilizer with carbon-based additives, the carbon-based additives are mixed with fine potassium fertilizer granules. The fine potassium fertilizer granules can be white potassium fertilizer and / or red potassium fertilizer, and as previously mentioned, the carbon-based additives may also include one micronutrient or a combination of multiple micronutrients. The mixed potassium fertilizer granules and carbon additives are then placed under high pressure, where they are co-compacted to form flakes or sheets. The flakes or sheets are then broken into smaller pieces to produce… Figures 2 to 6 The particles shown.

[0032] Co-compacted potash fertilizers with carbon-based additives may contain powdered carbon-based additives at various incorporation rates. In an exemplary embodiment, the incorporation rate of the carbon-based additive is approximately 0.01% to 5% by weight of the total fertilizer granules, and more specifically, approximately 0.1% to 1% by weight of the potash fertilizer. However, it should be understood that the incorporation rate of the carbon-based additive can be increased or decreased to achieve the desired effect on the co-compacted potash fertilizer.

[0033] It should be understood that the various operations used in the methods of this teaching can be performed in any order and / or simultaneously, as long as this teaching remains operational. Furthermore, it should be understood that the apparatus and methods of this teaching may include any number or all of the described instances, as long as this teaching remains operational.

[0034] Various examples of systems, apparatuses, and methods have been described herein. These examples are given by way of illustration only and are not intended to limit the scope of the claimed invention. Furthermore, it should be understood that the various features of the described examples can be combined in various ways to produce many other examples. In addition, while various materials, sizes, shapes, constructions, and positions have been described for the disclosed examples, other materials, sizes, shapes, constructions, and positions may be used without departing from the scope of this disclosure, in addition to those disclosed.

[0035] Those skilled in the art will recognize that the subject matter herein may include fewer features than those shown in any single example above. The examples described herein are not intended to exhaustively list all possible combinations of features of the subject matter. Therefore, these examples are not mutually exclusive combinations of features; rather, the various examples may include combinations of different single features selected from different single examples, as understood by those skilled in the art. Furthermore, elements described with respect to one example may be implemented in other examples, even if not described in such examples, unless otherwise stated.

[0036] While dependent claims may refer to a specific combination with one or more other claims in the claims, other instances may also include combinations of dependent claims with the subject matter of each of the other dependent claims, or combinations having one or more features with other dependent or independent claims. Such combinations are presented herein unless otherwise indicated.

[0037] The inclusion of any of the foregoing documents is limited to the purpose of not incorporating subject matter contrary to the express disclosure herein. The inclusion of any of the foregoing documents is also limited to the purpose of not incorporating claims contained therein. The inclusion of any of the foregoing documents is further limited to the purpose of not incorporating any definitions provided therein, unless expressly included herein.

[0038] For the purposes of interpreting the claims, it is clearly intended that the provisions of 35 U.S.SC §112(f) shall not be invoked unless the specific terms “apparatus” or “step” are recited in the claims.

Claims

1. A fertilizer product comprising multiple fertilizer granules, each granule comprising: Fertilizer carrier composition; and Carbon-based additives with functional groups.

2. The fertilizer product as described in claim 1, wherein, The carbon-based additive includes carbon black acid, and the functional group includes a carboxyl group.

3. The fertilizer product as described in claim 1, wherein, The functional group includes hydroxyl groups.

4. The fertilizer product as described in claim 1, wherein, The fertilizer carrier composition includes a potassium-containing composition.

5. The fertilizer product as described in claim 4, wherein, The potassium-containing composition is selected from the group consisting of potassium chloride, potassium chloride, potassium sulfate, potassium magnesium sulfate, potassium nitrate, potassium hydroxide, anhydrous potassium magnesium alum, polyhalite, and combinations thereof.

6. The fertilizer product as described in claim 1, wherein, The fertilizer carrier composition includes a phosphate-containing composition.

7. The fertilizer product as described in claim 6, wherein, The phosphate-containing composition is selected from the group consisting of monoammonium phosphate, sulfur-fortified monoammonium phosphate, diammonium phosphate, monosuperphosphate, triple superphosphate, struvite, and combinations thereof.

8. The fertilizer product as described in claim 1, wherein, The carbon-based additive is contained within the fertilizer carrier composition.

9. The fertilizer product as described in claim 1, wherein, The carbon-based additive is formed as a coating on the outer surface of the fertilizer particles.

10. The fertilizer product as described in claim 1, wherein, The carbon-based additive is present in an amount of about 0.01% by weight to about 5% by weight relative to the total weight of the fertilizer particles.

11. The fertilizer product as described in claim 1, wherein, The carbon-based additive comprises dried particles with an average particle size of about 120 nm to about 500 μm, and wherein the functional groups are present on the outer surface of the dried particles.

12. The fertilizer product as described in claim 1, wherein, The carbon-based additive includes a liquid.

13. A fertilizer product comprising a plurality of fertilizer granules, each granule comprising: Fertilizer carrier composition; and Multiple carbon black acid particles with an average particle size of approximately 120 nm to approximately 500 μm.

14. The fertilizer product as described in claim 13, wherein, The fertilizer carrier composition includes a potassium-containing composition.

15. The fertilizer product as described in claim 14, wherein, The potassium-containing composition is selected from the group consisting of potassium chloride, potassium chloride, potassium sulfate, potassium magnesium sulfate, potassium nitrate, potassium hydroxide, anhydrous potassium magnesium alum, polyhalite, and combinations thereof.

16. The fertilizer product as described in claim 13, wherein, The fertilizer carrier composition includes a phosphate-containing composition.

17. The fertilizer product as described in claim 16, wherein, The phosphate-containing composition is selected from the group consisting of monoammonium phosphate, sulfur-fortified monoammonium phosphate, diammonium phosphate, monosuperphosphate, triple superphosphate, struvite, and combinations thereof.

18. The fertilizer product as described in claim 13, wherein, The plurality of carbon black acid particles are contained within the fertilizer carrier composition.

19. The fertilizer product as described in claim 13, wherein, The plurality of carbon black acid particles are present in an amount of about 0.01% to about 5% by weight relative to the total weight of the fertilizer particles.

20. A method for preparing a fertilizer product containing carbon-based additives, the method comprising: Provide fertilizer compositions containing macronutrients; The fertilizer composition is combined with carbon black acid in an amount of about 0.01% to about 5% by weight of the total weight of the fertilizer composition; This forms multiple fertilizer granules.

21. The method of claim 20, wherein, The fertilizer composition comprises a phosphate slurry, and the step of forming a plurality of fertilizer granules includes: The carbon black acid is introduced into the slurry in the drum; and The phosphate-containing slurry is co-granulated with the carbon black acid therein to form the plurality of fertilizer granules.

22. The method of claim 20, wherein, The fertilizer composition comprises a potassium-containing composition, and the step of forming a plurality of fertilizer granules includes: The carbon black acid is mixed with the potassium-containing composition; The carbon black acid and the potassium-containing composition are compacted to form a sheet product; and The flaky product is crushed to prepare the plurality of fertilizer granules.

23. The method of claim 20, wherein, The carbon black acid comprises dried particles with an average particle size of about 120 nm to about 500 μm.

24. The method of claim 20, wherein, The carbon black acid is a liquid.

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