Micronutrients enriched urea fertilizer composition

Abstract

A fertilizer composition comprising at least one micronutrient and a solidified urea melt, and methods for producing and using the same are disclosed. The at least one micronutrient may be homogeneously distributed in the solidified urea melt and / or encapsulated within at least one carrier. The fertilizer composition may include zinc, boron, iron, manganese, molybdenum, selenium, silicon, and / or copper.

Description

DESCRIPTIONMICRONUTRIENTS ENRICHED UREA FERTILIZER COMPOSITION CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of Indian Application No.202441084953, filed November 6, 2024, the contents of which are incorporated into the present application by reference in its entirety.BACKGROUND OF THE INVENTIONA. Field of the Invention

[0002] This invention is in the field of fertilizers. Generally, it concerns a fertilizer composition that includes a solidified urea melt and at least one micronutrient which is homogeneously distributed within the solidified urea melt.B. Description of Related Art

[0003] With the increase in global population, demand for food is ever increasing. To meet the growing demand, agricultural crop yields should be dramatically increased. Fertilizer is one of the major factors that contributes to high crop yields. Fertilizers are chemical compositions that are added to plants, soil, and / or water in order to provide nutrients that promote growth. Nitrogen (N), phosphorus (P), and / or potassium (K) are present in many fertilizers, as these three primary nutrients play key roles in plant nutrition and growth.

[0004] In addition, micronutrients can also greatly improve crops. To improve soil fertility, farmers are applying micronutrient fertilizers in separate applications from primary nutrients and sometimes from other micronutrients. These applications are labor intensive processes. Due to the small amount of micronutrients needed per hectare, there is a chance of overapplication, under-application, and misapplication (e.g., wrong time, wrong ratio, etc.). Further, separate applications are more laborious. To resolve some of these issues, micronutrients have been applied with earners to help bulk up the material to be applied so that quantities are more easily controlled and placement in the soil is easier. In some instances, the micronutrients have been applied together with primary nutrients. However, application together with primary nutrients risks over application or under application of either the primary nutrient or the micronutrient, or both.SUMMARY OF THE INVENTION

[0005] A solution to at least some of the problems discussed above has been discovered. A fertilizer composition is disclosed herein that utilizes a nitrogen fertilizer component such as molten urea and at least one micronutrient component. The micronutrient component may be homogeneously distributed within the solidified urea melt. The micronutrient may include zinc, boron, iron, copper, manganese, molybdenum, selenium, silicon, and / or combinations thereof. In some instances, the fertilizer may include both the solidified urea melt and the micronutrients embedded in a carrier. In some instances, the at least one micronutrient is in the form of a particulate. In some instances, at least a portion of the at least one micronutrient and / or at least a portion of the solidified urea melt may be a recycled micronutrient and / or recycled urea. Further, applying the composition may eliminate a separate step for applying the micronutrient to a plant. In addition, the combination of urea as well as micronutrients in a single package fertilizer (such as the composition) increases the simplicity and efficiency of supplying a plant with needed nutrients and micronutrients. Further, some micronutrients can have dual functions as a crop nutrients as well as a crop protectant from biotic and / or abiotic stress that can add a benefit to the primary nutrient that the micronutrients is combined.

[0006] One aspect of the invention is directed to fertilizer compositions. The fertilizer compositions may contain at least one micronutrient and a matrix of solidified urea melt. In some aspects, at least one micronutrient may be homogeneously distributed in the matrix of solidified urea melt. In some aspects, the solidified urea melt forms a continuous phase in the matrix. In some aspects, the at least one micronutrient may be in the form of a particulate. In some aspects, at least a portion of the at least one micronutrient and / or at least a portion of the solidified urea melt may be recycled. In some aspects, the composition may include 0.0001 to 5 wt.% the at least one micronutrient or a combination of micronutrients, or at least any one of, at most any one of, equal to any one of, or between any two of 0.0001 wt.%, 0.005 wt.%, 0.001 wt.%, 0.05 wt.%, 0.01 wt.%, 0.1 wt. %, 0.5 wt. %, 1 wt. %, 1.5 wt. %, 2 wt. %, 2.5 wt. %, 3 wt. %, 3.5 wt. %, 4 wt. %, 4.5 wt. %, or 5 wt. % of the at least one micronutrient or a combination of micronutrients based on the weight of the fertilizer composition, or any range thereof. In some aspects, the at least one micronutrient may include zinc, boron, iron, manganese, molybdenum, selenium, silicon, and / or copper. In some aspects, the composition may further include an inhibitor. In some aspects, the composition may further include a carrier. In some aspects, the composition may further include a binder, pH adjuster, a buffer, a filler, a crosslinker, and / or a rheology modifier.

[0007] In some aspects, the composition may have a specific density of the one or more micronutrients and / or a carrier carrying the one or more micronutrients is within + / - 20 % of a specific density of a urea melt.

[0008] In another aspect of the invention is directed to a method of making a fertilizer composition. In several aspects, the method may include the steps of, (a) contacting at least one micronutrient with a urea melt, and (b) mixing to homogeneously distribute the at least one micronutrient in the urea melt. In some aspects, step (b) occurs in a granulator. In some aspects, at least a portion of the at least one micronutrient and / or at least a portion of the urea melt may be recycled. In some aspects, the at least one micronutrient and / or the urea melt may further include a carrier.

[0009] In some instances, the micronutrients may be contacted as a liquid, a slurry, or a solid such as a powder. In some aspects, step (a) may include pre-heating of micronutrient or micronutrient mixture in a solid or liquid form to remove free moisture, to increase the flowability, to match the carrier fluid temperature, to avoid solid cluster formation and / or to achieve uniform mixing.

[0010] In some aspects, micronutrients are introduced / contacted with urea used in the fertilizer composition at other stages in the production of the fertilizer composition. In some instances, micronutrients may be introduced into the undersized fertilizer granules that are recycled back to the granulator. In some instances, oversized fertilizer granules may be moved to a crusher and upon crushing form small granules and / or powder. The small granules and / or powder may be recycled back to the granulator. In some instances, micronutrients may be introduced into the crusher that are eventually recycled to the granulator, thus increasing the amount of micronutrients in the granulator. In some instances, micronutrients may be introduced into the crushed granules and / or powder that are eventually recycled to the granulator, thus increasing the amount of micronutrients in the granulator.

[0011] In some aspects, micronutrients are introduced / contacted with urea used in the fertilizer composition at multiple stages such as in a urea melt before granulation, in the granulator, in a crusher, and / or in a granule and / or powder fertilizer composition recycle line.

[0012] Some aspects pertain to a system for producing a fertilizer composition. In some aspects, the system may include a source of urea melt, a mixer fluidly connected to the source of urea melt, and a granulator fluidly connected to the mixer. In some aspects, the system mayinclude a source of a micronutrient, optionally a mixer fluidly connected to the source of urea melt, a granulator that can be optionally fluidly connected to the mixer, optionally a granule separator that separates granules by size, optionally one or more granule and / or crushed granule recycle lines, and / or optionally a crusher to crush oversized granules.

[0013] The following includes definitions of various terms and phrases used throughout this specification.

[0014] The term “fertilizer” is defined as a material applied to soils or to plant tissues to supply one or more plant nutrients essential or beneficial to the growth of plants and / or stimulants or enhancers to increase or enhance plant growth. Non-limiting examples of fertilizers include materials having one or more of urea, ammonium nitrate, calcium ammonium nitrate, urea calcium sulfate adduct, one or more superphosphates, binary NP fertilizers, binary NK fertilizers, binary PK fertilizers, NPK fertilizers, molybdenum, zinc, copper, boron, cobalt, and / or iron. In some aspects, fertilizers include agents that enhance plant growth and / or enhance the ability for a plant to receive the benefit of a fertilizer, such as, but not limited to bio stimulants, urease inhibitors, and nitrification inhibitors.

[0015] The term “nutrient” is defined as a chemical element or substance used for the normal growth and development of a plant. Non-limiting examples of nutrients include N, P, K, Ca, Mg, S, B, Cu, Fe, Mn, Mo, Zn, Se, and Si or compounds thereof.

[0016] The term “micronutrient” is defined as a chemical element or substance used in trace amounts for the normal growth and development of a plant. Non-limiting examples of micronutrients include B, Cu, Fe, Mn, Mo, Zn, Se, and Si or compounds thereof.

[0017] The term “granule” can include a solid material. A granule can have a variety of different shapes, non-limiting examples of which include a spherical, a puck, an oval, a rod, an oblong, or a random shape. The term “prill” refers to a solid globule of a substance formed by the congealing of a liquid. The term “pellet” refers to a rounded, compressed mass of fertilizer. The term “powder” refers to dry particles produced by the grinding, crushing, precipitating, or disintegration of a fertilizer composition.

[0018] The terms “about” or “approximately” are defined as being close to as understood by one of ordinary skill in the art. In one non-limiting embodiment, the terms are defined tobe within 10%, preferably within 5%, more preferably within 1%, and most preferably within 0.5%.

[0019] The terms “wt.%,” “vol.%,” or “mol.%” refers to a weight percentage of a component, a volume percentage of a component, or molar percentage of a component, respectively, based on the total weight, the total volume of material, or total moles, that includes the component. In a non-limiting example, 10 grams of component in 100 grams of the material is 10 wt.% of component.

[0020] The term “substantially” and its variations are defined to include ranges within 10%, within 5%, within 1%, or within 0.5%.

[0021] The terms “inhibiting” or “reducing” or “preventing” or “avoiding” or any variation of these terms, when used in the claims and / or the specification, includes any measurable decrease or complete inhibition to achieve a desired result.

[0022] The term “effective,” as that term is used in the specification and / or claims, means adequate to accomplish a desired, expected, or intended result.

[0023] The use of the words “a” or “an” when used in conjunction with any of the terms “comprising,” “including,” “containing,” or “having” in the claims, or the specification, may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.”

[0024] The words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”), or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

[0025] The fertilizer composition and methods of producing the fertilizer composition of the present invention can “comprise,” “consist essentially of,” or “consist of’ particular ingredients, components, compositions, steps, etc. disclosed throughout the specificationBRIEF DESCRIPTION OF THE DRAWINGS

[0026] Advantages of the present invention may become apparent to those skilled in the art with the benefit of the following detailed description and upon reference to the accompanyingdrawings. While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings. The drawings may not be to scale.

[0027] The FIGURE is a non-limiting flowchart for a method of making a fertilizer according to one example of the present invention.DETAILED DESCRIPTION OF THE INVENTION

[0028] The fertilizer composition may include at least one micronutrient and a solidified urea melt. The at least one micronutrient may be homogeneously distributed in the solidified urea melt. The micronutrient may include zinc, boron, iron, copper, manganese, molybdenum, selenium, silicon, and / or combinations thereof. In some instances, the fertilizer may include both the solidified urea melt and the micronutrient embedded in a carrier. In some instances, the at least one micronutrient is in the form of a particulate. In some instances, at least a portion of the at least one micronutrient and / or at least a portion of the solidified urea melt may be a recycled micronutrient and / or a recycled urea. Applying the composition may eliminate a separate step for applying micronutrients to a plant. In addition, the combination of urea as well as micronutrients in a single package fertilizer (such as the composition) increases the simplicity and efficiency of supplying a plant with needed nutrients and micronutrients. Further, some micronutrients can have dual functions as a crop nutrients as well as a crop protectant from biotic and / or abiotic stress that may enhance the use of the urea.

[0029] These and other non-limiting aspects of the present invention are discussed in further detail in the following sections.A. Fertilizer Compositions

[0030] The fertilizer compositions may contain at least one micronutrient and a solidified urea melt. In some aspects, the compositions may contain at least one micronutrient homogeneously distributed in the solidified urea melt. In some aspects, the solidified urea melt may form a continuous phase. In some aspects, the at least one micronutrient may be in the form of a particulate. The particulate may have an average diameter of 10 to 1000 micrometers, such as, between, at most, or at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 20, 30, 40, 50, 60, 70, 80, 90, 100, 200, 300, 400, 500, 600, 700, 800, or 900 micrometers. In some aspects, at least a portion of the at least one micronutrient and / or at least a portion of the solidified urea melt may be recycled, such as undersized solidified urea melt particles, oversized solidifiedurea melt particles, crushed oversized urea melt particles, and / or crushed undersized solidified urea melt particles. In some aspects, the at least one micronutrient may include zinc, boron, iron, manganese, molybdenum, selenium, silicon, and / or copper. In some aspects, the composition may further include an inhibitor, such as a nitrification inhibitor and / or a urease inhibitor. In some aspects, the composition may further include a carrier. In some aspects, the composition may further include a binder, a crosslinker, a pH adjuster, a buffer, a filler, and / or a rheology modifier.

[0031] In some aspects, The inhibitor can be a urease inhibitor or a nitrification inhibitor, or a combination thereof. In one aspect, the composition can comprise a urease inhibitor and a nitrification inhibitor. In one aspect, the inhibitor can be a urease inhibitor. Suitable urease inhibitors include, but are not limited to, N-(n-butyl) thiophosphoric triamide (NBTPT) and phenylphosphorodiamidate (PPDA). In one aspect, the composition can comprise NBTPT or PPDA, or a combination thereof. In another aspect, the inhibitor can be a nitrification inhibitor. Suitable nitrification inhibitors include, but are not limited to, 3,4-dimethylpyrazole phosphate (DMPP), dicyandiamide (DCD), thiourea (TU), 2-chloro-6-(trichloromethyl)-pyridine (Nitrapyrin), 5-ethoxy-3-trichloromethyl-l,2,4-thiadiazol, which is sold under the tradename Terrazole®, by OHP Inc., USA, 2-amino 4-chloro 6-methyl pyrimidine (AM), 2-mercaptobenzothiazole (MBT), or 2-sulfanilamidothiazole (ST), and any combination thereof. In one aspect, nitrification inhibitor can comprise DMPP, DCD, TU, nitrapyrin, 5-ethoxy-3-trichloromethyl-l,2,4-thiadiazol, AM, MBT or ST, or a combination thereof. In one aspect, the composition can comprise NBTPT, DMPP, TU, DCD, PPDA, nitrapyrin, 5-ethoxy-3-trichloromethyl-l,2,4-thiadiazol, AM, MBT, or ST or a combination thereof.

[0032] In some aspects, the carrier may be chitosan, crosslinked chitosan, a gum, a carbohydrate, inorganic nano porous materials, and / or combinations thereof. In some aspects, a inorganic nano porous material carrier may include zeolite, biochar, hydroxyapatite, and / or combinations thereof. In some aspects, the carrier comprises plaster of paris, flour, chalk powder, starch, gluten, kaolin, bentonite, colloidal silica, silica, dried distillers grains with solubles, lignin, a synthetic polymer, a wax, chitin, glycoaminoglycans, pectins, hyaluronic acid, chondroitin sulphate, dermatan sulphate, alginic acid, polymannuronic acid, polyguluronic acid, polyglucuronic acid, amylose, amylopectin, callose, chitosan, polygalactomannan, dextran, xanthan, keratan sulphate, MgO, CaO, bone mill powder, rice husk, CaCO3, Na2CO3, K2CO3, KH2PO4, NaHCO3, and / or MgCO3.

[0033] In some aspects, the fertilizer composition may also contain surfactant to stabilize the composition. In some aspects, surfactants may include nonionic surfactants and / or Tween 80 (polysorbate 80, polyoxyethylene sorbitan monooleate). In some aspects, the nonionic surfactants are used as a stabilizer.

[0034] In certain aspects, fertilizer composition can further contain the plant growth promoters such as enzymes, seaweed extracts, plant extracts, proteins, amino acids, microorganisms, innoculants, bio-innoculants, salicylic acid, humic acids, bio-stimulants, plant growth hormones, fulvic acids, protein hydrolases, or combinations thereof.

[0035] In some aspects, the fertilizer composition may contain 0.00001 to 5 wt.% the at least one micronutrient or a combination of micronutrients, or at least any one of, at most any one of, equal to any one of, or between any two of 0.00001 wt.%, 0.00002 wt.%, 0.00003 wt.%, 0.00004 wt.%, 0.00005 wt.%, 0.00006 wt.%, 0.00007 wt.%, 0.00008 wt.%, 0.00009 wt.%, 0.0001 wt.%, 0.0002 wt.%, 0.0003 wt.%, 0.0004 wt.%, 0.0005 wt.%, 0.0006 wt.%, 0.0007 wt.%, 0.0008 wt.%, 0.0009 wt.%, 0.001 wt.%, 0.002 wt.%, 0.003 wt.%, 0.004 wt.%, 0.005 wt.%, 0.006 wt.%, 0.007 wt.%, 0.008 wt.%, 0.009 wt.%, 0.01 wt.%, 0.02 wt.%, 0.03 wt.%, 0.04 wt.%, 0.05 wt.%, 0.06 wt.%, 0.07 wt.%, 0.08 wt.%, 0.09 wt. %, 0.1 wt. %, 0.2 wt.%, 0.3 wt.%, 0.4 wt.%, 0.5 wt.%, 0.6 wt.%, 0.7 wt.%, 0.8 wt.%, 0.9 wt. %, 1 wt. %, 1.1 wt. %, 1.2 wt.%, 1.3 wt.%, 1.4 wt.%, 1.5 wt.%, 1.6 wt.%, 1.7 wt.%, 1.8 wt.%, 1.9 wt. %, 2 wt. %, 1.1 wt. %, 2.2 wt.%, 2.3 wt.%, 21.4 wt.%, 2.5 wt.%, 2.6 wt.%, 2.7 wt.%, 2.8 wt.%, 2.9 wt. %, 3 wt. %, 3.1 wt. %, 3.2 wt.%, 3.3 wt.%, 3.4 wt.%, 3.5 wt.%, 3.6 wt.%, 3.7 wt.%, 3.8 wt.%, 3.9 wt. %,, 4 wt. %, 4.1 wt. %, 4.2 wt.%, 4.3 wt.%, 4.4 wt.%, 4.5 wt.%, 4.6 wt.%, 4.7 wt.%, 4.8 wt.%, 4.9 wt. %„ or 5 wt. % of the at least one micronutrient or a combination of micronutrients based on the weight of the fertilizer composition. In some aspects, the fertilizer composition can contain 70 wt. % to 99.99999 wt. % or at least any one of, at most any one of, equal to any one of, or between any two of 70 wt. %, 75 wt. %, 80 wt. %, 85 wt. %, 90 wt. %, 95 wt. %, 96 wt. %, 97 wt. %, 98 wt. %, 99 wt. %, 99.1 wt. %, 99.2 wt. %, 99.3 wt. %, 99.4 wt. %, 99.5 wt. %, 99.6 wt. %, 99.7 wt. %, 99.8 wt. %, 99.9 wt. %, 99.91 wt. %, 99.92 wt. %, 99.93 wt. %, 99.94 wt. %, 99.95 wt. %, 99.96 wt. %, 99.97 wt. %, 99.98 wt. %, 99.99 wt. %, 99.991 wt. %, 99.992 wt. %, 99.993 wt. %, 99.994 wt. %, 99.995 wt. %, 99.996 wt. %, 99.997 wt. %, 99.998 wt. %, 99.999 wt. %, 99.9991 wt. %, 99.9992 wt. %, 99.9993 wt. %, 99.9994 wt. %, 99.9995 wt. %, 99.9996 wt. %, 99.9997 wt. %, 99.9998 wt. %, 99.9999 wt. %, 99.99991 wt. %,99.99992 wt. %, 99.99993 wt. %, 99.99994 wt. %, 99.99995 wt. %, 99.99996 wt. %, 99.99997 wt. %, 99.99998 wt. %, 99.99999 wt. % of solidified urea melt.

[0036] In some aspects, the fertilizer does not contain or is substantially free of a binder, filler, pH buffer, urease inhibitor, and / or nitrification inhibitor.

[0037] The fertilizer composition can be of any suitable shape. Non-limiting shapes include spherical, cuboidal, cylindrical, puck shape, oval, and oblong shapes. In some aspects, the fertilizer composition can be of cylindrical shape with a circular, elliptical, ovular, triangular, square, rectangular, pentagonal, or hexagonal cross section, although cylindrical shaped core having a cross-section of other shapes can also be made. In some aspects, the fertilizer composition is in the form of a liquid, powder, prill, granule, and / or pellet.

[0038] The fertilizer composition can be in the form of a powder / granule and can have desirable physical properties such as desired levels of abrasion resistance, granule strength, pelletizability, hygroscopicity, granule shape, and size distribution.

[0039] The fertilizer described herein can be comprised in a composition useful for application to plant, soil, or plant and soil. In addition to the fertilizer composition, the composition may include other fertilizer compounds, micronutrients, primary nutrients, additional urea, additional nitrogen nutrients, insecticides, herbicides, or fungicides, or combinations thereof.

[0040] The fertilizer described herein can also be included in a blended composition comprising other fertilizers. The other fertilizers can be monoammonium phosphate (MAP), diammonium phosphate (DAP), muriate of potash (MOP), monopotassium phosphate (MKP), triple super phosphate (TSP), rock phosphate, single super phosphate (SSP), ammonium sulfate, and the like.B. A Method and / or A System Capable of Making a Fertilizer Composition

[0041] One aspect of the present invention is directed to a method for making a fertilizer composition. In several aspects, the method may include the steps of, (a) contacting at least one micronutrient with a urea melt, and (b) mixing to homogeneously distribute the at least one micronutrient in the urea melt. In some aspects, step (a) and / or (b) may occur in a granulator. In some aspects, at least a portion of the at least one micronutrient and / or at least a portion of the urea melt may be from recycled micronutrients and / or recycled urea. In some aspects, the at least one micronutrient and / or the urea melt may further include in a carrier.

[0042] In some instances, the micronutrients may be contacted as a liquid, a slurry, or a solid such as a powder. In some aspects, step (a) may include pre-heating of micronutrient or micronutrient mixture in a solid or liquid form to remove free moisture, to increase the flowability, to match the carrier fluid temperature, to avoid solid cluster formation and / or to achieve uniform mixing.

[0043] In some aspects, micronutrients are introduced / contacted with urea used in the fertilizer composition at other stages in the production of the fertilizer composition. In some instances, micronutrients may be introduced into the undersized fertilizer granules that are recycled back to the granulator. In some instances, oversized fertilizer granules may be moved to a crusher and upon crushing form small granules and / or powder. The small granules and / or powder may be recycled back to the granulator. In some instances, micronutrients may be introduced into the crusher that are eventually recycled to the granulator, thus increasing the amount of micronutrients in the granulator. In some instances, micronutrients may be introduced into the crushed granules and / or powder that are eventually recycled to the granulator, thus increasing the amount of micronutrients in the granulator.

[0044] In some aspects, micronutrients are introduced / contacted with urea used in the fertilizer composition at multiple stages such as in a urea melt before granulation, in the granulator, in a crusher, and / or in a granule and / or powder fertilizer composition recycle line.

[0045] The FIGURE shows a flow chart of a method and / or system 100 for making a fertilizer composition according to one example of the present invention. Referring to the FIGURE, a urea melt such as 110, such as a urea melt produced by an urea solution evaporator (not shown), can optionally be contacted with an at least one micronutrient 112 which is in a solid and / or a suspension form in a mixer 102 to homogeneously distribute the at least one micronutrient 112 in the urea melt 110 to form a micronutrient and urea combination 114. The generated micronutrient and urea combination 114 can be pumped to a granulator 104, where the micronutrient and urea combination 114 can optionally be combined with the micronutrients 112 in the granulator 104 to form a granulated mixture 116. Upon cooling, the granulated mixture 116 is screened by size by using a separator such as 106. The desired size granulated mixture forms a fertilizer composition 118. In some instances, undersized granules such as 122 are recycled back to the granulator 104. In some instances, micronutrients 112 are introduced into the undersized granules 122 that are recycled to the granulator, thus increasing the amount of micronutrients in the granulator 104. In some instances, the micronutrients 112introduced into the undersized granules 122 are introduced as a liquid, a slurry, or a solid such as a powder. In some instances, oversized granules such as 120 may be moved to a crusher 108 and upon crushing form small granules and / or powder such as 124. The small granules and / or powder 124 may be recycled back to the granulator 104. In some instances, micronutrients 112 are introduced into the crusher 108, the oversized granules such as 120, and / or the small granules and / or powder 124 that are eventually recycled to the granulator 104, thus increasing the amount of micronutrients in the granulator 104. In some instances, the micronutrients 112 introduced as a liquid, a slurry, or a solid such as a powder.

[0046] In some instances, the method / system may have a particle size distribution (PSD) of the micronutrients to optimize and / or match the bulk density for good solid-solid mixing. In some instances, the micronutrients specific gravity is such that it matches or is similar (such as within 20%, 15%, 10%, 5%, 1%, 0.5% 0.1% or any number therebetween or range thereof) to the specific gravity of the urea melt or a carrier fluid. In some instances, modifying the micronutrient liquid or a micronutrient mixture specific gravity to match with urea melt (60 to 99 wt%) specific gravity may achieve a high degree of uniformity of distribution of the micronutrients in the fertilizer composition. In some instances, the micronutrients density is such that it matches or is similar (such as within 20%, 15%, 10%, 5%, 1%, 0.5% 0.1% or any number therebetween or range thereof) to the density of the urea melt or a carrier fluid. In some instances, modifying the micronutrient liquid or a micronutrient mixture specific gravity to match with urea melt (60 to 99 wt%) density may achieve a high degree of uniformity of distribution of the micronutrients in the fertilizer composition. In some instances, pre-heating of solid or liquid form of micronutrient or micronutrient mixture may remove free moisture, increase flowability, and / or be similar to the carrier fluid temperature and / or the urea melt (e.g., 90 to 150 °C) (such as within 20%, 15%, 10%, 5%, 1%, 0.5% 0.1% or any number therebetween or range thereof) can help avoid solid cluster formation and / or can help to achieve uniform mixing. In some instances, mixing fluids with different specific gravities and polarity using inline hi-speed mixers may give a high degree of mixing (e.g., increase homogeneity) and reduce mixing time, and / or also limit biuret formation. In some instances, the method of injecting micronutrient liquids before an evaporator and / or in a recycle stream facilitates a higher degree of uniformity in the product stream. In some instances, the method may include optimizing the particle size distribution (PSD) of the micronutrient or micronutrient mixture to achieve a high degree of mixing and reduce dust generation during granulation. In some instances, the method may include injecting a binder, pH adjuster, a buffer, a filler, acrosslinker, and / or a rheology modifier in the micronutrient stream to improve granule quality and to reduce dust generation. In some instances, the rheology modifiers can include rosin, lignosulfonate, PEG, poly urethane, castor oil and its derivatives, and / or a combination thereof. In some instances, the pH adjuster can include poly phosphates, poly sulfides of calcium, magnesium and potassium, and / or a combination thereof. In some instances, the binders can include exfoliated sodium / magnesium / calcium / aluminum silicate clays, and / or a combination thereof.

[0047] In some instances, the urea melt may include melted nano urea or may include nanoparticles of urea. In some instances, the micronutrients may include zinc, boron, iron, manganese, molybdenum, selenium, silicon, copper (Cu, Mn, Si, B, Fe, Mo, Se, Zn) and / or a combination thereof. In some aspects, the micronutrients are nanoparticles. The carrier can include flour, plaster of paris, chitosan, crosslinked chitosan, a gum, a carbohydrate, and / or inorganic nano porous materials. In some aspects, surfactant are also included in one or more of the solutions.

[0048] In some instances, the urea and micronutrients can be contacted in the presence of water to form a slurry / homogenized solution. In certain aspects, the urea can be contacted with the micronutrients to form the slurry / homogenized solution. In some aspects, the micronutrients can be added to the urea, urea solution, and / or urea melt at a concentration of 0.00001 wt. % to 5 wt. % or at least any one of, at most any one of, equal to any one of, or between any two of 0.00001 wt. %, 0.0001 wt. %, 0.001 wt. %, 0.01 wt. %, 0.1 wt. %, 1 wt. %, 2 wt. %, 3 wt. %, 4 wt. %, and 5 wt. % of micronutrients. In some aspects, the urea and micronutrients can be contacted at 40 °C to 140 °C, or at least any one of, at most any one of, equal to any one of, or between any two of 40 °C, 45 °C, 50 °C, 55 °C, 60 °C, 65 °C, 70 °C, 75 °C, 80 °C, 85 °C, 90 °C, 95 °C, 100 °C, 105 °C, 110 °C, 115 °C, 120 °C, 125 °C, 130 °C, 135 °C, and 140 °C. In some aspects, the urea melt comprises 4 - 15% of water, such as at, greater than, less than, or between 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 % or any range thereof. In some aspects the micronutrients can be contacted at 90 °C to 140 °C, or at least any one of, at most any one of, equal to any one of, or between any two of 90 °C, 95 °C, 100 °C, 105 °C, 110 °C, 115 °C, 120 °C, 125 °C, 130 °C, 135 °C, and 140 °C, or any range thereof.

[0049] In some aspects, a carrier may have a concentration of 0.1 wt. % to 30 wt. % or at least any one of, at most any one of, equal to any one of, or between any two of 0.1 wt. %, 0.5wt. %, 1 wt. %, 2 wt. %, 5 wt. %, 10 wt. %, 15 wt. %, 20 wt. %, 25 wt. %, and 30 wt. %, or any range thereof, in a mixture of micronutrients, urea, and the carrier.

[0050] In some aspects, the mixer, such as mixer 102 in the figure, can be a high speed mixer, an in-line mixer, a T-mixer, etc. In some aspects, the mixer is fluidly connected to the source of urea melt (not shown). In some aspects the source of urea melt may comprise at least an evaporator. In some aspects, the evaporator may be able to convert urea solution into urea melt and inject the urea melt into mixer. In some aspects, the urea solution may contain a concentration of 70 wt. % to 80 wt. % or at least any one of, at most any one of, equal to any one of, or between any two of 70 wt. %, 71 wt. %, 72 wt. %, 73 wt. %, 74 wt. %, 75 wt. %, 76 wt. %, 77 wt. %, 78 wt. %, 79 wt. %, and 80 wt. % of urea, or any range thereof. In some aspects, the urea melt may contain a concentration of 90 wt. % to 99.9999 wt. % or at least any one of, at most any one of, equal to any one of, or between any two of 90 wt. %, 91 wt. %, 92 wt. %, 93 wt. %, 94 wt. %, 95 wt. %, 96 wt. %, 97 wt. %, 98 wt. %, 99 wt. %, and 99.9 wt. % of urea, or any range thereof. The mixer may, in some instances, accept urea melt and mix micronutrients into the urea melt. The mixer may homogenously mix the micronutrients into the urea melt. The mixer may mix the urea melt and micronutrients before the urea melt is completely solidified. The mixer may mix the urea melt and micronutrients before the mixture is introduced into a granulator. The mixer may mix the urea melt and micronutrients before the mixture is cooled to below 15 °C below the melting temperature of urea.

[0051] In some aspects, the in-line mixer can be a high-shear mixer. In some aspects, the mixer can be a liquid-powder mixer. In some aspects, the high-shear mixer and / or the liquid-powder mixer may perform mixing with a shear rates of 1500 – 3500 rpm or at least any one of, at most any one of, equal to any one of, or between any two of 1500 rpm, 1600 rpm, 1700 rpm, 1800 rpm, 1900 rpm, 2000 rpm, 2100 rpm, 2200 rpm, 2300 rpm, 2400 rpm 2500 rpm, 2600 rpm, 2700 rpm, 2800 rpm, 2900 rpm, 3000 rpm, 3100 rpm, 3200 rpm, 3300 rpm, 3400 rpm, and 3500 rpm of shear rate, or any range thereof. In some aspects, the temperature in the mixer can be at 100 °C to 175 °C, or at least any one of, at most any one of, equal to any one of, or between any two of 100 °C, 105 °C, 110 °C, 115 °C, 120 °C, 125 °C, 130 °C, 135 °C, 140 °C, 145 °C, 150 °C, 155 °C, 160 °C, 165 °C, 170 °C, and 175 °C, or any range thereof. In some aspects, the pressure in the mixer can be at 1 to 10 bar, or at least any one of, at most any one of, equal to any one of, or between any two of 1 bar, 2 bar, 3 bar, 4 bar, 5 bar, 6 bar, 7 bar, 8 bar, 9 bar, and 10 bar, or any range thereof.

[0052] In certain aspects, the granulator is incorporated with a dryer or is externally connected to dryer. In some aspects, the composition can be heated and / or dried at 35 °C, 40 °C, 45 °C, 50 °C, 55 °C, 60 °C, 65 °C, 70 °C, 75 °C, 80 °C, 85 °C, 90 °C, 95 °C, 100 °C or greater, or any temperature or range thereof or there between, to reduce the volume of the resulting fertilizer solution or to form a fertilizer powder / granule. The amount of water, e.g., moisture, in the dried fertilizer powder / granule can be less than 0.6 wt.%, 0.5 wt.%, 0.4 wt.%, 0.3 wt.%, 0.2 wt.%, 0.1 wt.%, or less, or any amount or range thereof or there between. In several aspects, the formed fertilizer powder / granules may have an average diameter size ranging from about 2 nm to about 5 mm.

[0053] In some aspects, a method of making the fertilizer composition can include additional nutrients such as phosphorous, potassium, plant growth promoters, bio- stimulants, microorganisms, and / or combinations thereof in one or more of the solutions used to produce the fertilizer.

[0054] In one aspect, a system for producing a fertilizer composition by using the described method above. In some aspects, the system may include a source of urea melt, a source of a micronutrient, optionally a mixer fluidly connected to the source of urea melt, a granulator that can be optionally fluidly connected to the mixer, optionally a granule separator that separates granules by size, optionally one or more granule and / or crushed granule recycle lines, and / or optionally a crusher to crush oversized granules.C. Method of Using the Fertilizer Composition

[0055] The fertilizer composition of disclosed herein can be used in methods of increasing the amounts of nitrogen and micronutrients and other nutrients in plant and soil for enhancing plant growth. In some instances, urea is applied at basal as well as top dressing for various crops during vegetative growth. The fertilizer composition may deliver the micronutrients along with nitrogen in split applications as per the plant need. Such methods may include applying to a plant, and / or applying to the soil an effective amount of a composition comprising the fertilizer composition disclosed herein. The method may include increasing the growth and yield of crops, trees, ornamentals, etc. such as, for example, Gazania, Maize, Marigold, palm, coconut, rice, wheat, corn, barley, oats, and soybeans. The method may include applying the fertilizer composition disclosed herein to at least one of a plant, a soil, an organism, a liquid carrier, a liquid solvent, etc.

[0056] Non-limiting examples of plants that may benefit from the fertilizer disclosed herein include vines, trees, shrubs, stalked plants, ferns, etc. The plants may include orchard crops, vines, ornamental plants, food crops, timber, and harvested plants. The plants may include Gymnosperms, Angiosperms, and / or Pteridophytes. The Gymnosperms may include plants from the Araucariaceae, Cupressaceae, Pinaceae, Podocarpaceae, Sciadopitaceae, Taxaceae, Cycadaceae, and Ginkgoaceae families. The Angiosperms may include plants from the Aceraceae, Agavaceae, Anacardiaceae, Annonaceae, Apocynaceae, Aquifoliaceae, Araliaceae, Arecaceae, Asphodelaceae, Asteraceae, Berberidaceae, Betulaceae, Bignoniaceae, Bombacaceae, Boraginaceae, Burseraceae, Buxaceae, Canellaceae, Cannabaceae, Capparidaceae, Caprifoliaceae, Caricaceae, Casuarinaceae, Celastraceae, Cercidiphyllaceae, Chrysobalanaceae, Clusiaceae, Combretaceae, Comaceae, Cyrillaceae, Davidsoniaceae, Ebenaceae, Elaeagnaceae, Ericaceae, Euphorbiaceae, Fabaceae, Fagaceae, Grossulariaceae, Hamamelidaceae, Hippocastanaceae, Illiciaceae, Juglandaceae, Lauraceae, Lecythidaceae, Lythraceae, Magnoliaceae, Malpighiaceae, Malvaceae, Melastomataceae, Meliaceae, Moraceae, Moringaceae, Muntingiaceae, Myoporaceae, Myricaceae, Myrsinaceae, Myrtaceae, Nothofagaceae, Nyctaginaceae, Nyssaceae, Olacaceae, Oleaceae, Oxalidaceae, Pandanaceae, Papaveraceae, Phyllanthaceae, Pittosporaceae, Platanaceae, Poaceae, Polygonaceae, Proteaceae, Punicaceae, Rhamnaceae, Rhizophoraceae, Rosaceae, Rubiaceae, Rutaceae, Salicaceae, Sapindaceae, Sapotaceae, Simaroubaceae, Solanaceae, Staphyleaceae, Sterculiaceae, Strelitziaceae, Styracaceae, Surianaceae, Symplocaceae, Tamaricaceae, Theaceae, Theophrastaceae, Thymelaeaceae, Tiliaceae, Ulmaceae, Verbenaceae, and / or Vitaceae family.

[0057] The effectiveness of compositions comprising the fertilizer composition disclosed herein may be ascertained by measuring the amount of growth such as plant height, number of branches, total number of flowers and buds, kernel and stover yields, cob length, weight of the harvested portion of the plant, and / or number of seed, etc. at various times after applying the fertilizer composition to plants. The effectiveness of the fertilizer composition may also be directly compared to other fertilizer compositions by doing a side-by-side comparison in the same soil under the same conditions.EXAMPLES

[0058] The present invention will be described in greater detail by way of specific examples. The following examples are offered for illustrative purposes only, and are notintended to limit the invention in any manner. Those of skill in the art will readily recognize a variety of noncritical parameters which can be changed or modified to yield essentially the same results.Example 1Producing a Fertilizer Composition

[0059] A fertilizer composition can be produced by the following method.

[0060] Contacting at least one micronutrient (Cu, Mn, Si, B, Fe, Mo, Se, Zn) with a urea melt in a mixer at any temperature between 90 to 125 °C followed by a high speed mixing can create a homogeneously distributed micronutrient in the urea melt. The at least one micronutrient in the urea melt can be uniformly distributed in a matrix of solidified urea melt upon cooling. The composition can include 0.00001 to 5 wt.% of the at least one micronutrients based on the weight of the fertilizer composition. In some instances, Cu, Mn, Si, B, Fe, Mo, Se, Zn or other microelements optionally can be added to the already combined urea melt and at least one micronutrient. The generated material can be cooled and / or can be further dried at 80 °C for 12 hours. In some instances, at least a portion of the at least one micronutrient and / or at least a portion of the urea melt can be recycled in a granulator. In some instances, the at least one micronutrient and / or the urea melt further can include a carrier in the mixture.Example 2Fertilizer composition example product

[0061] As non-limiting examples, the final fertilizer composition product can contain any of the following amount of nutrients based on the micronutrients source used along with a urea melt. The weight percentages are based on the weight of the composition.1. Urea + Zinc (0.1 – 2 wt.% zinc) (zinc sources can be chelated zinc, zinc oxide and / or zinc sulfate)2. Urea + Boron (0.01 – 0.1 wt.% boron) (boron source can be colemanite, boric acid and / or borax)3. Urea + Zinc (0.02 – 0.1 wt.% zinc) and Boron (0.01 – 0.02% wt.% boron) (zinc sources can be chelated zinc, zinc oxide and / or zinc sulfate; boron source can be colemanite, boric acid and / or borax)4. Urea + Manganese (0.02 – 0.5 wt.% manganese) (manganese source can be chelated manganese, manganese acetate, manganese sulfate, and / or manganese dioxide)5. Urea + Molybdenum (0.005 – 0.04 wt.% molybdenum) (molybdenum source can be ammonium molybdate)6. Urea + Selenium (0.001 – 0.003 wt.% selenium) (selenium source can be organic and / or inorganic forms of selenium)7. Urea + Silicon (0.05 – 0.2% wt.% silicon) (silicon source can be silicon dioxide, calcium silicates, and / or potassium silicates)8. Urea + Copper (0.02 – 1% wt.% copper) (copper source can be copper sulfate and / or chelated copper).

Claims

CLAIMS1. A fertilizer composition comprising:at least one micronutrient, anda matrix of solidified urea melt,wherein the at least one micronutrient is homogeneously distributed in the matrix of solidified urea melt.

2. The fertilizer composition of claim 1, wherein the solidified urea melt forms a continuous phase in the matrix.

3. The fertilizer composition of claim 1, wherein the at least one micronutrient is in the form of a particulate.

4. The fertilizer composition of any one claims 1-3, wherein at least a portion of the at least one micronutrient and / or at least a portion of the solidified urea melt is recycled.

5. The fertilizer composition of any one claims 1-4, wherein the composition comprises 0.0001 to 5 wt.% of the at least one micronutrients based on the weight of the fertilizer composition.

6. The fertilizer composition of any one claims 1-5, wherein the at least one micronutrient comprises zinc, boron, iron, manganese, molybdenum, selenium, silicon, and / or copper.

7. The fertilizer composition of any one claims 1-6, wherein the composition further comprises an inhibitor.

8. The fertilizer composition of any one claims 1-7, wherein the composition further comprises a carrier.

9. The fertilizer composition of any one claims 1-8, wherein the composition further comprises a binder, pH adjuster, a buffer, a filler, a crosslinker, and / or a rheology modifier.

10. The fertilizer composition of any one claims 1-9, where a specific density of the one or more micronutrients and / or a carrier carrying the one or more micronutrients is within + / - 20 % of a specific density of a urea melt.

11. A method of producing the fertilizer composition of any one claims 1-10, the method comprising the steps of:(a) contacting at least one micronutrient with a urea melt; and(b) mixing to homogeneously distribute the at least one micronutrient in the urea melt.

12. The method of claim 11, wherein step (a) comprises contacting the micronutrient with the urea melt occurs in a granulator.

13. The method of any one claims 11 to 12, wherein at least a portion of the at least one micronutrient and / or at least a portion of the urea melt is recycled.

14. The method of any one claims 11 to 13, wherein the at least one micronutrient and / or the urea melt further comprises in a carrier.

15. A system for producing a fertilizer composition, the system comprising:a source of urea melt;a mixer fluidly connected to the source of urea melt; anda granulator fluidly connected to the mixer.

Images