UAN 34 fertilizer formulation with high nitrogen content and improved storage stability and its production method

Abstract

This invention presents a new UAN 34 (9) formulation designed to solve the technical issues of existing Urea Ammonium Nitrate (UAN) formulations UAN 34 (9) has a 34% nitrogen content and a crystallization temperature ranging from -2°C to 0°C. The formulation is produced using a special method and an innovative activator (4) consisting of at least one organic acid, one inorganic acid, and sulfate-free copper compounds. This activator (4) ensures the stability of UAN 34 (9), imparts a blue color, and naturally minimizes corrosion, reducing the need for additional inhibitors. The final product has a specific gravity of 1.360 g / L and can be stored for at least three years without phase separation or crystallization. UAN 34 offers an efficient, stable, and cost-effective nitrogen source for agricultural applications, supporting sustainable farming practices, increasing crop yield, and reducing environmental impact.

Description

[0001] UAN 34 Fertilizer Formulation with High Nitrogen Content and Improved Storage Stability and Its Production Method

[0002] Technical Field

[0003] The invention relates to nitrogen fertilization used in the agricultural sector to support plant growth and development. Specifically, it covers UAN (Urea Ammonium Nitrate) formulations, which are liquid nitrogen fertilizers. UAN formulations are liquid fertilizer solutions containing 32% nitrogen, known as UN32 or UAN-32, and are widely used worldwide. The invention aims to solve storage and crystallization issues while increasing the nitrogen content of these fertilizers.

[0004] The invention focuses on overcoming technical problems related to the storage and crystallization of UAN solutions with high nitrogen content. UAN formulations consist of solutions such as UAN 32, which contains 32% nitrogen, and these solutions are obtained by dissolving urea and ammonium nitrate in water. However, increasing the nitrogen content to 34% (UAN 34) has not been produced so far due to problems such as phase separation, crystallization, and reduced commercial viability during storage. The proposed solution involves the use of an activator containing at least one organic acid, one inorganic acid, and a sulfate-free copper compound. This activator stabilizes the UAN 34 solution, preventing crystallization and phase separation issues and providing a higher nitrogen content. Additionally, this activator ensures that the solution can be stored without degradation for at least three years.

[0005] State of the Art

[0006] Nitrogen is one of the most important plant nutrients used to enhance plant growth and productivity in agriculture. One of the widely used formulations in the field of liquid nitrogen fertilization is Urea Ammonium Nitrate (UAN) solutions. The current UAN formulations are typically UAN 28, UAN 30, and the most commonly used UAN 32. UAN 32 is known for its 32% nitrogen content and is extensively used in the agricultural sector worldwide. These formulations provide an effective solution to meet the nitrogen needs of plants. UAN formulations are solutions of urea and ammonium nitrate in water. However, these formulations produced with current technology have certain limitations. Specifically, developing a UAN formulation with a higher nitrogen content (for example, UAN 34) presents technical challenges. The main problems encountered during the development of the UAN 34 formulation are as follows:

[0007] A. Storage Issues: UAN compounds with high nitrogen content experience phase separation and crystallization issues during storage. In existing formulations, even a 2% increase in nitrogen content raises the precipitation and crystallization temperature by 8- 10°C. This makes the product commercially unusable. Additionally, UAN compounds undergo phase changes within a minimum of 6 months after the production process is completed, leading to a decrease in the quality of the final product.

[0008] B. Production Techniques: With commercially known production models and techniques, the highest commercially available product is UAN 32. This formulation contains 32% (320 g) pure nitrogen in a 1 kg solution. Producing a formulation with a higher nitrogen content is not possible with current techniques.

[0009] C. Crystallization Issues: A 2% increase in nitrogen content raises the salt out (crystallization) by 8-10°C, leading to precipitation and crystallization, which reduces the commercial value of the product.

[0010] D. Quality and Stability: The quality and stability of UAN compounds decrease during the storage period after production, leading to declines in product quality. This causes significant limitations in commercial and agricultural use.

[0011] E. Specific Gravity Increase: The specific gravity of the highest commercially available product, UAN 32, is a maximum of 1.320 kg / L, and a 2% increase in content requires a 20 g increase in specific gravity. The specific gravity of the intended UAN 34 produced with this technique needs to be 1.340 kg / L, and the salt out temperature needs to be +(8- 10) °C.

[0012] F. Commercial Production Insufficiency: For the above reasons, UAN 34 has not been commercially produced to date. The percentages of components and physical properties of the currently produced UAN (Urea Ammonium Nitrate) formulations (UAN 28, UAN 30, UAN 32) are as follows: As the nitrogen percentage increases (respectively 28%, 30%, 32%), the ammonium nitrate (40%, 42%, 45%) and urea (30%, 33%, 35%) ratios in the formulations increase, while the water percentage (30%, 25%, 20%) decreases. Additionally, the increase in nitrogen percentage raises the specific gravity (1 .283 kg / L, 1.303 kg / L, 1.320 kg / L) and the salt out temperature (-18_-16 °C, -10_-8 °C, -2_0 °C).

[0013] Based on the research in the literature, a PCT application with reference WO2007133821A2 has been found. This application presents a new composition and method for liquid fertilizers, particularly Urea Ammonium Nitrate (UAN) solutions. These compositions aim to enhance the stability and maximize the effectiveness of UAN solutions. For this purpose, various stabilizers and corrosion inhibitors are added to the solutions. Stabilizers prevent the degradation of UAN solutions during storage, while corrosion inhibitors minimize corrosion that may occur in metal containers and storage tanks. WO2007133821A2 uses stabilizers to increase the stability of UAN solutions during storage. However, our invention, UAN 34, contains a developed activator with a higher nitrogen content (34%) and completely eliminates phase separation and crystallization issues during storage. The WO2007133821A2 patent suggests the addition of corrosion inhibitors. Our invention, on the other hand, minimizes the corrosion effect thanks to the components in the activator, thereby simplifying the production process and reducing costs.

[0014] Another research in the literature a PCT application with reference WO2017037262A1 has been found. This patent relates to a method and device used in the production of UAN solutions. It specifically focuses on optimizing the mixing and heating processes of UAN solutions. By optimizing these processes, the patent aims to increase the homogeneity and effectiveness of the solutions. This method ensures the consistent and efficient production of UAN solutions. WO2017037262A1 uses special mixing and heating methods to increase the homogeneity of UAN solutions. Our invention, while ensuring homogeneity, produces a UAN 34 solution with 34% nitrogen content by using a special activator. This provides a higher nitrogen content that is not possible with existing production techniques. Although the WO2017037262A1 patent ensures homogeneity, it does not solve the crystallization issues that high nitrogen content solutions face during storage. Our invention eliminates this issue with its low crystallization temperature (-2°C - 0°C). Another research in the literature a PCT application with reference WO2017037262A1 has been found. This patent presents an optimized method for the production and use of Urea Ammonium Nitrate (UAN) solutions. This method aims to increase the efficiency of fertilizers by optimizing various components and production parameters. The patent explains the ideal ratios and mixing techniques of the necessary components for more effective use of UAN solutions in agriculture. US10457609B2 focuses on component optimization to increase the efficiency of UAN solutions. However, it does not provide information on increasing the nitrogen content to 34%. Our invention offers a UAN 34 solution with 34% nitrogen content, providing higher efficiency. While US10457609B2 focuses on optimizing various components, it does not provide a solution for the storage stability of high nitrogen content solutions. Our invention offers a formulation that maintains stability for 3 years by using a special activator.

[0015] Another research in the literature a European patent application with reference EP3541780B1 has been found. This patent relates to a method and device used in the production of Urea Ammonium Nitrate (UAN) solutions. It specifically focuses on increasing the stability and homogeneity of UAN solutions. This patent ensures the production of more stable and effective UAN solutions by using special mixing and heating techniques. EP3541780B1 suggests special mixing and heating techniques to increase the stability and homogeneity of UAN solutions. However, our invention produces a UAN 34 solution with a higher nitrogen content (34%) using a special activator and maintains its stability during storage with a low crystallization temperature (-2°C - 0°C). Although the EP3541780B1 patent increases stability, it does not provide a definitive solution to the crystallization issues faced by high nitrogen content solutions during storage. Our invention completely eliminates this issue using the developed special activator, ensuring that the product can be stored for a long time without degradation.

[0016] Although these inventions aim to improve certain aspects of UAN solutions, they have deficiencies in the production and storage stability of the UAN 34 solution with high nitrogen content. Our invention addresses these issues, providing a more efficient and stable fertilizer formulation. Specifically, with a 34% nitrogen content, low crystallization temperature, and long storage life, it offers a significant innovation in the agricultural sector. The shortcomings of the current UAN formulations highlight the need for a fertilizer formulation with higher nitrogen content, stability, and long-term storability. In this context, the development of a new formulation, UAN 34, offers significant innovation and improvement potential in the agricultural sector.

[0017] The UAN 34 subject to this invention has a 34% nitrogen content, providing a high nitrogen content and improved storage stability that cannot be produced with existing techniques. This formulation, prepared using a special activator, eliminates phase separation and crystallization issues, ensuring that the product can be stored without degradation for at least three years. This new formulation aims to increase efficiency and sustainability in agriculture by surpassing the limitations of existing technology.

[0018] Objective of the Invention

[0019] The primary objective of the invention is to provide a more effective fertilizer formulation by increasing the nitrogen content of existing UAN (Urea Ammonium Nitrate) solutions. Specifically, the aim is to achieve a 34% nitrogen content with the UAN 34 formulation. This aims to meet the nitrogen needs of plants more efficiently, surpassing the currently highest nitrogen content UAN 32 (32% nitrogen) used in agriculture.

[0020] Another important objective of the invention is to resolve phase separation, crystallization, and degradation issues that high nitrogen content fertilizers experience during storage. In this regard, a special activator containing at least one organic acid, one inorganic acid, and copper element, obtained through a special production technique and prepared through a three-stage separate production process, is used. This activator, which gives a blue color to the finished material, does not have copper sulfate or similar sulfate-containing compounds.

[0021] Increasing the nitrogen content in existing UAN formulations leads to crystallization issues. Another objective of the invention is to eliminate these issues. If UAN 34 were produced with the standard UAN production method and its specific gravity was 1360 g / L, the salt-out temperature (crystallization) would need to be (+10°C to +15°C). However, by using the activator subject to the invention, the UAN 34 formulation is produced with a low crystallization temperature (-2 to 0°C), minimizing the risk of crystallization during storage and use of the solutions.

[0022] Commonly used corrosion inhibitors in fertilizer solutions increase production costs and complicate the production process. The invention aims to minimize the need for extra corrosion-inhibiting components and simplify the production process while reducing costs, thanks to the corrosion-inhibiting properties of the OCC activator.

[0023] The production process of the UAN 34 formulation aims to develop a more efficient and effective method compared to existing techniques. In this context, the combination of organic and inorganic acids with copper compounds used in the production stages through a special technique and a three-stage production process aims to achieve a stable fertilizer formulation.

[0024] The aim is to develop a fertilizer formulation with high nitrogen content and long-term storability, thereby increasing agricultural productivity. This ensures that plants receive the necessary nitrogen more effectively, resulting in higher yields and better-quality products. Additionally, the goal is to reduce environmental impacts and support sustainable agricultural practices by using less fertilizer.

[0025] Fertilizers with higher nitrogen content can achieve the same effect with smaller quantities. This leads to reduced transportation and storage costs. The UAN 34 formulation offers environmental and economic advantages with less packaging and lower transportation costs.

[0026] In order to achieve the above objectives, the invention is a urea ammonium nitrate (UAN) fertilizer formulation with at least 34% nitrogen content, high storage stability, and low crystallization temperature properties. It contains ammonium nitrate, urea, water, at least one organic acid, at least one inorganic acid, and at least one activator that includes sulfate-free copper, giving the formulation a blue color due to its mixture composition.

[0027] In conclusion, this invention aims to address various shortcomings of existing UAN solutions and provide a more efficient, stable, and economical fertilizer solution for agricultural production. With high nitrogen content, improved storage stability, and enhancements in the production process, UAN 34 carries significant innovation and development potential in the agricultural sector.

[0028] Description of Figures

[0029] Figure- 1 is a schematic view of the production method of the UAN 34 formulation subject to the invention.

[0030] Figure-2 is a table of laboratory test results for the product prepared with the UAN 34 formulation subject to the invention.

[0031] Description of Part References

[0032] 1. Organic Acid

[0033] 2. Inorganic Acid

[0034] 3. Sulfate-free Copper

[0035] 4. Activator

[0036] 5. Activator Mixing Tank

[0037] 6. Urea

[0038] 7. Ammonium Nitrate

[0039] 8. UAN 34 Mixing Tank

[0040] 9. UAN 34

[0041] 10. Water

[0042] Detailed Description Of Invention

[0043] This invention presents a new UAN 34 (9) formulation developed to solve the technical problems encountered by existing urea ammonium nitrate (UAN) formulations. UAN 34 (9) has a 34% nitrogen content and a salt out temperature range of -2°C to 0°C. This formulation is obtained using a special production method and an activator (4).

[0044] The activator (4) consists of components including at least one organic acid (1), one inorganic acid (2), and sulfate-free copper (3). These components are combined using the production technique of the invention and subjected to a three-stage production process. This activator (4) imparts a blue color to the finished material and does not contain copper sulfate or similar sulfate-containing compounds. The absence of copper sulfate or similar sulfate-containing compounds in the activator (4) aims to minimize the need for corrosion inhibitors, simplify the production process, and reduce costs. Compounds such as copper sulfate can cause corrosion and may require the use of additional corrosion inhibitors. The activator (4) of the invention offers a more effective and economical solution by minimizing this need. Additionally, preventing the use of sulfate compounds reduces environmental impacts and contributes to sustainable agricultural practices.

[0045] The activator (4) is mixed with urea (6) and ammonium nitrate (7) solutions in a specific sequence. This process is carried out as follows to ensure the stability of the mixture and prevent crystallization: a) Adding the required water (10) to the UAN 34 mixing tank (8) according to the amount to be produced (the water can be heated to a temperature of 60-90 degrees depending on the required amount), b) Mixing at least one organic acid (1) and one inorganic acid (2), adding sulfate-free copper (3) to the mixture, heating to a specific temperature (preferably up to 180 degrees), then cooling (preferably to 30 degrees) to prepare the activator (4) and adding it to the activator mixing tank (5) and mixing, c) Adding half of the required urea (6) to the UAN 34 mixing tank (8) and mixing, d) Adding half of the required ammonium nitrate (7) to the UAN 34 mixing tank (8) and mixing, e) Adding the remaining half of the required urea (6) to the UAN 34 mixing tank (8) and mixing, f) Adding the remaining half of the required ammonium nitrate (7) to the UAN 34 mixing tank (8) and mixing, g) Letting the product settle and filter (preferably letting it settle for 1 day), h) Filling the filtered product into the desired packaging.

[0046] Temperature and Density Control:

[0047] During the mixing process, the temperature and density of the mixture are monitored. The final product has a specific gravity of 1360 g / L and a crystallization temperature of - 2° to 0°C. The activator (4) used in the product preparation stage must be reduced to a temperature of 20-40°C after reaching 150-180°C before being added to the main production tank. When adding it to the main production tank, the urea (6) and ammonium nitrate (7) should be divided into two parts and added in the sequence of 14 urea + 14 ammonium nitrate + 14 urea + 14 ammonium nitrate; it should not be added to the tank all at once.

[0048] The new UAN 34 (9) formulation can be effectively stored for a minimum of three years without phase separation or crystallization. This enhances the long-term stability and usability of the product.

[0049] The UAN 34 (9) formulation consists of the following components:

[0050] Ammonium nitrate (7): One of the main components of the UAN compound. The ammonium and nitrate nitrogens it contains play an important role in providing the nitrogen necessary for plant growth and development. In the UAN 34 (9) formulation, the preferred amount of ammonium nitrate by weight is 51%, with a usable range of 49-54%.

[0051] Urea (6): The other main component of the UAN compound, and the urea nitrogen it contains provides the nitrogen that plants need. In the UAN 34 (9) formulation, the preferred amount of urea by weight is 38%, with a usable range of 36-39%.

[0052] Water (10): The solvent component of the UAN compound, necessary for dissolving the solid granular materials. In the UAN 34 (9) formulation, the preferred amount of water by weight is 10.7%, with a usable range of 9-12%. Pure water can also be used in place of the water (10) used in the formulation.

[0053] Activator (4): One of the innovative components of the invention. It contains at least one inorganic acid (2), at least one organic acid (1), and a sulfate-free copper (3) compound. This activator ensures the stability of the UAN 34 (9) formulation and imparts a blue color. The blue color of the activator is due to the chemical properties of the special compounds it contains. This color change indicates that the formulation is properly mixed, and the activator is effective, also providing a visual check for the user. Thus, quality control in the production process is facilitated. The preferred amount of the activator by weight is 0.3%, with a usable range of 0.1-0.4%. These components are the main elements that provide the high nitrogen content, low crystallization temperature, and improved storage stability of the UAN 34 (9) formulation. Each component is critical to the effectiveness and functionality of the invention, ensuring the formulation works successfully.

[0054] The technical specifications of the UAN 34 (9) formulation are as follows:

[0055] A. 34% pure nitrogen

[0056] B. Specific Gravity: 1.360 g / L

[0057] C. Salt Out Temperature (Crystallization): -2°C - 0°C

[0058] The UAN 34 (9) formulation is suitable for various agricultural applications, providing an efficient and stable nitrogen source for plants. Improved stability and high nitrogen content contribute to better crop yield and reduced environmental impact, supporting sustainable agricultural practices and offering ease of use as it can be mixed with pesticides and herbicides.

[0059] Referring to Figure 1 , the production scheme shows the production process of the UAN 34 (9) formulation and the mixing stages of the components used. The production process is carried out by combining and mixing various inputs components at specific stages.

[0060] Organic Acid (1): A component used at the beginning of the production process.

[0061] Inorganic Acid (2): Used along with Organic Acid (1) and is an important component in preparing the activator (4).

[0062] Sulfate-free Copper (3): Another important component of the activator (4). It is used instead of copper sulfate or similar sulfate-containing compounds.

[0063] Urea (6): One of the main components that is a nitrogen source for the UAN 34 (9) formulation.

[0064] Ammonium Nitrate (7): Another nitrogen source used along with urea (6) to ensure the effectiveness of the formulation. Activator Mixing Tank (5): Organic acid (1), inorganic acid (2), and sulfate-free copper (3) components are mixed at a certain temperature (30-180°C) in this tank to prepare the activator (4). This activator (4) is a crucial component that ensures the stability of the UAN 34 (9) formulation.

[0065] UAN 34 Mixing Tank (8): The activator (4), urea (6), and ammonium nitrate (7) are mixed in this tank in a specific sequence to ensure homogeneity. The temperature of the tank is maintained between 20-60°C. First, half of the urea (6) and half of the ammonium nitrate (7) are added and mixed, then the remaining urea (6) and ammonium nitrate (7) are added and mixed.

[0066] UAN 34 (9): The final product is obtained by homogeneously mixing all components and processing them at the appropriate temperature. The UAN 34 (9) formulation offers superior properties with a 34% nitrogen content, low crystallization temperature (-2 to 0°C), and high storage stability.

[0067] This invention aims to address various shortcomings of existing UAN solutions and provide a more efficient, stable, and economical fertilizer solution for agricultural production. With high nitrogen content, improved storage stability, and enhancements in the production process, UAN 34 (9) eliminates the limits in the agricultural sector with its 34% nitrogen content. Its high impact on plants and rapid uptake represents a significant innovation and development potential in the use of UAN formulations in agriculture, changing the understanding of UAN formulation to date.

Claims

CLAIMS1. The invention is a urea ammonium nitrate (UAN) fertilizer formulation with at least 34% nitrogen content, high storage stability, and low crystallization temperature properties, characterized by containing ammonium nitrate (7), urea (6), water (10), at least one organic acid (1), at least one inorganic acid (2), and sulfate-free copper (3), and at least one activator (4) that gives the formulation a blue color due to its mixture composition.

2. The urea ammonium nitrate (UAN) fertilizer formulation according to claim 1 , characterized by containing 49-54% ammonium nitrate (7), 36-39% urea (6), 9-12% water (10), and 0.1 - 0.4% of at least one activator (4).

3. The urea ammonium nitrate (UAN) fertilizer formulation according to claim 2, characterized by containing 51% ammonium nitrate (7), 38% urea (6), 10.7% water (10), and 0.3% of at least one activator (4).

4. The urea ammonium nitrate (UAN) fertilizer formulation according to any of the preceding claims, characterized by the water (10) being pure water.

5. The invention is a method for producing a urea ammonium nitrate (UAN) fertilizer formulation with at least 34% nitrogen content, characterized by the following process steps:• adding the required amount of water (10) to the UAN 34 mixing tank (8) according to the produced quantity,• mixing at least one organic acid (1) and one inorganic acid (2), adding sulfate- free copper (3), heating and then cooling to prepare the activator (4), adding it to the activator mixing tank (5) and mixing,• adding and mixing half of the required urea (6) to the UAN 34 mixing tank (8),• adding and mixing half of the required ammonium nitrate (7) to the UAN 34 mixing tank (8),• adding and mixing the remaining half of the required urea (6) to the UAN 34 mixing tank (8),• adding and mixing the remaining half of the required ammonium nitrate (7) to the UAN 34 mixing tank (8),• letting the product settle and filter,• filling the filtered product into the desired packaging.

6. The production method according to claim 5, characterized by the water added to the UAN 34 mixing tank (8) being heated to a temperature of 60-90°C.

7. The production method according to claim 5, characterized by heating the components to 180°C and then cooling them to 30°C to prepare the activator containing at least one organic acid, at least one inorganic acid, and a sulfate-free copper compound.

8. The production method according to claim 5, characterized by containing at least one activator mixing tank (5) that ensures the homogeneous mixing of the activator (4) components.

9. The production method according to claim 5, characterized by containing at least oneUAN 34 mixing tank (8) that ensures the homogeneous mixing of the UAN 34 (9) components.

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