System and composition for encapsulated nanoionic urea using a protein-based encapsulation framework

Abstract

An encapsulated nano-ionic urea composition consisting of nano-sized urea particles encapsulated in digested protein shells, the encapsulated particles having a size distribution between 30 nanometers and 200 nanometers, the protein shells providing controlled release, improved bioavailability, and improved stability of the urea.

Description

Technical field of expertise:

[0001] The invention relates to the field of nano-fertilizers and advanced encapsulation technologies. Specifically, it relates to a system and composition for encapsulated nano-ionic urea, in which proteins act as encapsulating agents to ensure stability, uniform particle size, improved bioavailability, and agricultural efficiency. The system integrates thermodynamic modeling, biochemical encapsulation, and intelligent particle characterization modules to enable industrial-scale production and optimized performance. Background of the invention;

[0002] Global agriculture faces increasing challenges in meeting the growing demand for sustainable food production while simultaneously reducing the environmental impact of fertilizer use. Among the most widely used fertilizers, urea plays a central role due to its high nitrogen content and cost-effectiveness. However, conventional urea has significant drawbacks, including rapid dissolution, volatilization, leaching, and denitrification, all of which lead to substantial nutrient losses, reduced nitrogen use efficiency, and considerable pollution. These inefficiencies not only reduce crop yields but also contribute to greenhouse gas emissions and water pollution. In this context, the need for advanced fertilizer technologies that offer controlled release, improved bioavailability, and minimized losses has become increasingly urgent.

[0003] One approach to overcoming these limitations is the use of nanofertilizers. By reducing nutrient particles to the nanoscale, the surface area is significantly increased, thereby improving nutrient uptake and efficiency. In particular, nano-urea has shown remarkable potential to improve nitrogen uptake, reduce application frequency, and increase crop yield. However, producing stable and effective nano-urea remains a major technological challenge. The main difficulties lie in achieving a uniform particle size distribution, ensuring encapsulation stability, preventing aggregation, and enabling controlled release.Many existing nanofertilizer technologies are based on synthetic polymers or inorganic stabilizers, which can increase costs, impair biocompatibility, or negatively affect soil quality.

[0004] Encapsulation technology has emerged as a promising solution to these challenges by forming a protective matrix around nutrient molecules, which can regulate release rates and increase stability. Protein-based encapsulation, in particular, offers several advantages, such as biocompatibility, biodegradability, and a natural affinity for binding to urea molecules. Despite their potential, conventional protein-based encapsulation systems for urea have not been widely adopted, primarily due to the challenges of achieving consistent particle size, ensuring long-term storage stability, and integrating encapsulation into scalable industrial processes. Existing protein encapsulation techniques are often limited to laboratory-scale experiments, with limited adaptability for large-scale fertilizer production and application in diverse agricultural environments.

[0005] Furthermore, most existing methods for nano-encapsulating fertilizers lack the integration of advanced thermodynamic control and real-time particle monitoring. Temperature plays a critical role in protein folding and encapsulation, and without precise control, the encapsulated nano-urea size and stability can vary, reducing its effectiveness in agricultural applications. Similarly, particle size monitoring is crucial to ensure the nano-urea remains within the optimal size range to guarantee maximum bioavailability while preventing aggregation. Without adaptive monitoring and feedback mechanisms, conventional systems cannot guarantee the consistency required for reliable performance.

[0006] Another significant limitation of earlier technologies is their lack of flexibility in improving storage stability. Agricultural fertilizers often have to withstand variable storage conditions, including exposure to moisture and microbial contamination. Encapsulation systems that do not contain antimicrobials or stabilizers cannot meet this challenge, resulting in reduced shelf life and impaired efficacy by the time the product reaches the farmer.

[0007] Recognizing these shortcomings, there is a clear need for an advanced system that integrates protein-based encapsulation with precise thermodynamic control, adaptive particle monitoring, and optional antimicrobial stabilization. Such a system would not only produce a novel encapsulated nanoionic urea composition but also offer the scalability and robustness required for industrial applications. By combining the biochemical principles of protein encapsulation with advanced computational and thermodynamic control systems, the invention addresses the dual needs of sustainability and efficiency in fertilizer technology.The encapsulated nano-ionic urea product produced by this system is designed to offer controlled release, improved nitrogen utilization efficiency, reduced losses and higher yields, while minimizing the environmental footprint of fertilizer use.

[0008] Thus, the present invention closes a critical gap in the technology by providing a comprehensive capsule system and composition that overcomes the limitations of conventional ureas, nanofertilizers, and protein-based capsule systems. It represents a transformative step in agricultural technology by ensuring that the benefits of nanourea can be realized on a large scale and offering farmers a reliable, efficient, and sustainable fertilizer solution. Summary of the invention;

[0009] The invention introduces a novel system and composition for encapsulated nano-ionic urea that overcomes the shortcomings of conventional fertilizers and existing nano-encapsulation techniques. At the heart of the invention is a multi-component system designed to produce nano-urea particles within protein shells, exhibiting a uniform size distribution, high stability, and improved bioavailability. Unlike conventional fertilizers, which dissolve rapidly and lead to nutrient loss, the encapsulated nano-ionic urea produced by this system offers controlled release and improved nitrogen utilization efficiency, thereby increasing plant productivity and reducing environmental impact.

[0010] The system integrates a protein digestion and encapsulation unit, a thermodynamic control module, a particle size monitoring unit, and an encapsulation chamber, bringing these components together in a seamless operating framework. Proteins derived from plant or animal sources serve as the encapsulating medium. These proteins undergo controlled digestion and folding, enabling them to form a protective shell around ionic urea molecules. The encapsulation process ensures that the urea remains in a nano-ionic form, preventing premature dissolution and allowing for gradual release upon application to soil or plants.

[0011] A key innovation of the system is the thermodynamic control module, which maintains precise temperature control between 0°C and 60°C during encapsulation. Temperature is a crucial factor in determining particle size and uniformity, as it governs protein folding and nanoparticle formation. By maintaining strict thermal conditions and enabling real-time adjustments, the system ensures that the resulting encapsulated particles consistently fall within the optimal size range of 30–200 nm. This precise size control maximizes nitrogen bioavailability while minimizing the risk of particle aggregation or irregular release profiles.

[0012] The thermodynamic module is complemented by the particle size monitoring unit, which uses sensors and adaptive algorithms to track particle distribution in real time. This intelligent feedback system continuously analyzes particle size data, recalibrates the encapsulation parameters in case of deviations, and ensures consistency across production batches. Such real-time monitoring significantly improves reliability and makes the system suitable for industrial-scale fertilizer production.

[0013] The encapsulated composition itself represents a significant advancement over conventional fertilizers. It consists of nanoionic urea particles uniformly encased in protein shells, with optional stabilizers such as polyethylene glycol (PEG), polyvinyl alcohol (PVA), or propylene glycol to prevent aggregation during storage. To further enhance stability and shelf life, antimicrobial agents such as citric acid, silver nanoparticles, or zinc nanoparticles can be incorporated into the formulation. These additives ensure that the encapsulated urea remains effective under various agricultural conditions during transport and storage.

[0014] The resulting composition offers farmers a fertilizer with superior performance compared to conventional urea. When applied, the encapsulated nano-ionic urea provides a controlled release of nitrogen, ensuring a consistent supply to plants over an extended period. This reduces the frequency of fertilizer applications, lowers costs for farmers, and minimizes nitrogen loss to the environment. The protein shell not only stabilizes the urea compound but also improves its compatibility with soil systems, ensuring biocompatibility and sustainability.

[0015] Beyond agriculture, the encapsulated nano-ionic urea composition also finds application in catalytic processes, the production of adhesives and resins, detergents, flame retardants, and other industries where the controlled release of nitrogen compounds is advantageous. The system's versatility makes it valuable in multiple industrial sectors.

[0016] The scalability of the invention is another important feature. The modular design of the encapsulation system allows for integration into existing industrial fertilizer plants without significant modifications. Its energy-efficient thermodynamic control and adaptive monitoring reduce operating costs while ensuring consistent quality. The inclusion of machine learning algorithms further enhances its adaptability, enabling the system to evolve over time and optimize encapsulation protocols based on historical performance data.

[0017] Essentially, the invention transforms conventional fertilizer technology by combining biochemical principles of protein encapsulation with state-of-the-art thermodynamic and computational systems. The result is both a system and a product: a reliable, scalable, and sustainable means of producing encapsulated nanoionic urea. By addressing the long-standing challenges of nutrient loss, poor stability, and inefficiency associated with traditional urea use, the invention offers a comprehensive solution that supports higher crop yields, reduced environmental impact, and improved sustainability in global agriculture. Detailed description of the invention;

[0018] The present invention discloses a comprehensive system and a novel encapsulated nanoionic urea composition that together redefine the efficiency, stability, and sustainability of fertilizer technologies. Essentially, the invention aims at the convergence of protein-based encapsulation science, thermodynamic process control, and intelligent particle characterization, resulting in a composition that is uniform throughout at the nanoscale and a system that is scalable, adaptable, and suitable for continuous industrial production. The design of the invention reflects a response to the long-standing shortcomings of conventional urea fertilizers and the limitations of previous nano-fertilizer technologies.In particular, the invention addresses the recurring problems of rapid dissolution, uncontrolled nutrient release, particle aggregation, inconsistent bioavailability and limited environmental adaptability, all of which have restricted the practical application of nano-urea formulations in conventional agriculture.

[0019] The composition resulting from this invention consists of nanoionic urea particles encapsulated in a protein-based shell. These particles have a size distribution ranging from 30 to 200 nanometers, with stability and uniformity ensured by the capsule system design. The proteins, which can be of either plant or animal origin, act not only as passive carriers but also as active stabilizers by forming a biocompatible and biodegradable layer around the urea ions. The capsule shell serves several purposes: it prevents the premature release of nitrogen, regulates the solubility kinetics, improves compatibility with soil and plants, and protects the encapsulated urea from environmental damage or microbial attack.Unlike synthetic polymers traditionally used in encapsulation, protein shells are renewable, environmentally friendly and inherently compatible with agricultural ecosystems, ensuring that their use contributes positively to sustainable agricultural practices.

[0020] The production of this encapsulated composition is achieved through a specially designed system. At the heart of this system is the protein digestion and encapsulation unit, a sophisticated module that prepares and conditions the protein molecules to create suitable binding and encapsulation environments for urea ions. The proteins undergo controlled digestion, often involving enzymatic or thermally influenced folding mechanisms, which facilitate the formation of a nanoscale matrix capable of holding ionic urea in stable configurations. When introduced into this environment, the ionic urea solution is encapsulated as the proteins fold and self-assemble into nanoscale shells.This encapsulation does not occur randomly or loosely controlled, but is guided by the structural and biochemical properties of the proteins, which align with the ionic charges of the urea molecules, thus ensuring a firm and consistent encapsulation.

[0021] The system's thermodynamic control module plays a crucial role in the invention. Nanoscale encapsulation is extremely sensitive to temperature fluctuations, as protein folding, molecular interactions, and particle size determination are all governed by thermodynamic principles. The invention comprises a precise temperature control unit that maintains the encapsulation process between 0°C and 60°C, with finely tuned adjustments based on feedback from particle monitoring sensors. Lower temperatures tend to result in slower protein folding and larger particle sizes, while higher temperatures promote tighter folding and the formation of smaller particles. The ability to precisely control these parameters enables the system to continuously produce particles within the desired range of 30 to 200 nanometers.Furthermore, the thermodynamic module is designed to operate energy-efficiently by utilizing optimized heat exchange technologies that minimize energy consumption and thus ensure that the system can be integrated into industrial plants without excessive operating costs.

[0022] An equally critical element of the system is the particle characterization and monitoring unit. This module is equipped with advanced sensors, data analysis frameworks, and adaptive algorithms that continuously evaluate the particle size distribution during encapsulation. Unlike conventional systems where particle size is only checked after production, the invention integrates real-time monitoring, enabling immediate detection of deviations and dynamic adjustment of process parameters. If the particle sizes deviate beyond the defined range, the system automatically recalibrates the temperature, protein concentration, or encapsulation time to bring the distribution back within acceptable limits.The monitoring system also utilizes artificial intelligence and machine learning to learn from historical data, predict potential anomalies, and optimize future encapsulation runs. This intelligent adaptability ensures consistency, reduces waste, and improves the overall reliability of the encapsulation process, making it particularly well-suited for industrial applications.

[0023] The encapsulation chamber, which houses the interaction between the protein, urea, and stabilizers, is designed to ensure uniform mixing, controlled temperature regulation, and safe particle formation. The chamber integrates digestion, encapsulation, monitoring, and stabilization into a seamless workflow, ensuring that every step of the process is harmonized. The materials used in the chamber's construction were selected for their resistance to chemical corrosion, their ability to maintain sterility, and their compatibility with biochemical processes. Furthermore, the chamber is designed to allow for modular scalability, meaning that additional units can be connected in parallel or in series to increase production capacity without compromising uniformity or quality.

[0024] The system also allows for the optional integration of stabilizers and antimicrobial agents, further enhancing the properties of the encapsulated composition. Stabilizers such as polyethylene glycol (PEG), polyvinyl alcohol (PVA), and propylene glycol can be introduced during encapsulation to prevent particle aggregation and improve storage stability. These stabilizers work by forming an additional protective layer around the protein-coated urea particles, reducing the risk of clumping or precipitation during storage and transport. Antimicrobial agents such as citric acid, silver nanoparticles, zinc nanoparticles, or ammonium compounds can also be added to prevent microbial degradation of the protein shells. This is particularly critical in humid storage environments, where microbiological activity could otherwise compromise the integrity of the encapsulated particles.The optional inclusion of these active ingredients extends the shelf life of the composition and ensures that the product remains effective until it reaches the end consumer.

[0025] The resulting encapsulated composition offers several significant advantages over conventional urea fertilizers. First, the controlled release properties of the encapsulated nano-ionic urea ensure that nitrogen is delivered to plants gradually and evenly over an extended period. This reduces the need for repeated fertilizer applications, lowers labor costs, and minimizes environmental losses due to volatilization or leaching. Second, the nanoscale particle size improves absorption efficiency by plants, ensuring that a greater proportion of the applied nitrogen is actually utilized for growth and yield enhancement. Third, the protein-based capsule matrix provides biocompatibility and biodegradability, ensuring that the use of this fertilizer does not introduce harmful residues into soil or water systems.Fourthly, the optional inclusion of antimicrobial agents prevents product degradation during storage, thereby increasing reliability and ease of use for farmers.

[0026] The system is designed with industrial scalability in mind. Its modular architecture ensures that it can be implemented in small units for pilot studies or scaled up for mass production in fertilizer plants. The integration of energy-efficient modules, adaptive algorithms, and real-time monitoring reduces operational complexity and makes the system economically viable for large-scale deployment. Furthermore, the system is designed to be compatible with existing fertilizer production lines, requiring only minimal modifications for integration. This feature is particularly important for industrial adoption, as it allows manufacturers to integrate the technology without incurring prohibitive infrastructure costs.

[0027] Beyond its primary agricultural application, the encapsulated nanoionic urea composition also has cross-sectoral potential in other industries where the controlled release of nitrogen compounds is advantageous. In catalytic processes, the slow release of urea can improve reaction efficiency. In the production of resins and adhesives, the encapsulated form offers stability and controlled reactivity. In flame retardants and detergents, the controlled release of nitrogen can improve performance characteristics while minimizing waste. These additional applications expand the utility of the invention, making it valuable beyond agriculture and further strengthening its industrial relevance.

[0028] The invention also anticipates future developments in smart agriculture. By integrating the capsule system with digital monitoring and data acquisition platforms, the invention lays the foundation for precision farming. Farmers can be provided with data on the fertilizer release profile, soil nutrient availability, and plant nutrient uptake, enabling them to make informed decisions about fertilizer application. Such integration of smart technology with nano-encapsulation improves the sustainability and efficiency of agricultural practices and contributes to achieving global food security goals.

[0029] The system's design and encapsulated composition also ensure compliance with environmental regulations and sustainability goals. By reducing nitrogen losses, the invention directly lowers greenhouse gas emissions, particularly nitrous oxide, a potent greenhouse gas that contributes to global warming. Improving nitrogen utilization efficiency also reduces the need for excessive fertilizer application, thereby conserving natural resources and lowering costs for farmers. Furthermore, the biodegradable protein coatings ensure that the product leaves no harmful residues, which is consistent with sustainable agricultural practices and international regulatory frameworks.

[0030] In summary, the invention presents a transformative system and product that overcomes the persistent challenges of conventional urea fertilizers and existing nano-encapsulation technologies. Through the innovative integration of protein-based encapsulation, thermodynamic regulation, adaptive monitoring, and optional stabilization, the system produces a nanoionic urea composition that is uniform, stable, biocompatible, and highly effective. The invention offers not only a novel fertilizer product but also a robust and scalable system for its production, ensuring its applicability in various agricultural and industrial contexts.By combining biochemical principles with modern technological advances, the invention offers a comprehensive solution to the pressing global challenges of agricultural efficiency, environmental sustainability, and industrial adaptability.

Claims

[1] An encapsulated nano-ionic urea composition consisting of nano-sized urea particles encapsulated in digested protein shells, wherein the encapsulated particles have a size distribution between 30 nanometers and 200 nanometers, the protein shells providing controlled release, improved bioavailability and improved stability of the urea. [2] Composition according to claim 1, further comprising one or more stabilizers selected from polyethylene glycol (PEG), polyvinyl alcohol (PVA) or propylene glycol, wherein the stabilizers are configured to prevent aggregation and improve the storage stability of the encapsulated nanoionic urea. [3] Composition according to claim 1, wherein the encapsulated nanoionic urea further comprises antimicrobial agents selected from citric acid, silver nanoparticles, zinc nanoparticles or ammonium compounds, wherein the antimicrobial agents provide protection against microbial degradation and extend the shelf life of the composition.