A process for production of improved sulfur bentonite fertilizer composition with potassium fulvate

Abstract

The present invention discloses a process for producing a pastille-form sulfur bentonite composition supplemented with potassium fulvate. This composition comprises 1 to 20 weight percent potassium fulvate or any grade of fulvic acid, 75 to 90 weight percent elemental sulfur, and 5 to 15 weight percent bentonite clay material. The disclosed composition aims to enhance the value of sulfur bentonite fertilizer by effectively supplying potassium, fulvic acid, and sulfur.

Description

A process for production of improved sulfur bentonite fertilizer composition with potassium fulvate

[0001] A process for producing an improved sulfur-bentonite fertilizer composition with potassium fulvate to enhance its biostimulant effect and overall field performance.

[0002] Among fertilizers, sulfur bentonite is a crucial component widely utilized in agricultural practices worldwide. Its primary function is to rectify sulfur deficiencies in soil. Many soils globally, especially those subjected to intensive agricultural methods, may exhibit reduced sulfur levels, which can impede crop growth and diminish yields.

[0003] The application of sulfur bentonite provides a slow-release source of sulfur that plants can effectively utilize over an extended period, ensuring adequate nutrient availability. Sulfur bentonite is an essential component of fertilizer practices, offering both a nutrient source and a soil conditioner that enhances plant growth and soil health.

[0004] As the demand for efficient fertilizer formulations continues to grow, the significance of sulfur bentonite in promoting plant growth, ensuring nutrient availability, improving soil structure, and regulating pH levels become increasingly important. Consequently, sulfur bentonite fertilizer is emerging as a crucial practice for farmers seeking to optimize crop yields and sustain soil vitality.

[0005] Thus, the development of new compositions of sulfur bentonite represents a significant area of research and development among scientists, with innovative formulations being created worldwide.

[0006] One promising biostimulant material is potassium fulvate. Potassium fulvate is a natural organic compound formed from the decomposition of organic matter, primarily found in soil, peat, and lignite, and is commercially obtained from weathered coal and lignite. It belongs to the broader category of fulvic acids and humic substances, which are essential for soil health and plant growth.

[0007] Some key features include a variety of effects, such as facilitating increased nutrient uptake by plant roots and ensuring that they receive the essential elements needed for growth. Its application also contributes to improved soil aeration, water retention, and overall soil structure. This organic compound stimulates plant metabolism, resulting in stronger and faster-growing plants, ultimately leading to increased crop yields.

[0008] The molecular weight of potassium fulvate typically ranges from 300 to 500 daltons, while that of potassium humate generally varies from hundreds of thousands to millions of daltons. Potassium humate is a macromolecular mixture of organic salts, with only a small portion being absorbed and utilized by plants.

[0009] In contrast, potassium fulvate has a lower molecular weight, which facilitates easier absorption and utilization by crops. This is attributed to its composition of small organic acids, phenols, terpenes, and other compounds that can be directly assimilated by plants.

[0010] Additionally, potassium fulvate is soluble across all soil pH levels, whereas the solubility of potassium humate decreases at pH levels below 7.0. Furthermore, potassium fulvate is not as widely used for enhancing fertilizers as potassium humate.

[0011] In this invention, we have developed a process to produce a sulfur-bentonite fertilizer composition enriched with potassium fulvate, thereby harnessing its biostimulant effects to enhance overall field performance.

[0012] The disclosed composition aims to improve the sulfur bentonite fertilizer by incorporating potassium fulvate to integrate a biostimulant effect, thereby improving overall field performance. The potassium fulvate-humate integrated sulfur bentonite fertilizer composition comprises 1 to 20 weight percent potassium fulvate, 70 to 90 weight percent elemental sulfur, and 5 to 15 weight percent clay material.

[0013] The disclosed improved sulfur-bentonite fertilizer composition is based on a salt of fulvic acid, preferably potassium fulvate, which primarily acts as a plant biostimulant and soil conditioner. This composition also enhances the oxidation of elemental sulfur into a form that can be utilized by plants, due to increased organic content and microbial activity in the soil or rhizosphere.

[0014] The technical challenge lies in enhancing the efficacy of sulfur-bentonite fertilizers; this can be achieved by incorporating an additional biostimulant (potassium fulvate) to improve nutrient uptake, soil health, and plant growth. However, it is also essential to facilitate the oxidation of elemental sulfur because this contributes to better crop performance.

[0015] This innovation aims to improve sulfur-bentonite fertilizers by incorporating potassium fulvate, utilizing its biostimulant effects to enhance nutrient uptake, soil health and crop yields. The composition merges sulfur, clay and potassium fulvate to optimize production parameters and compositions.

[0016] The disclosed process and compositions serve not only as a source of sulfur (which is essential for plant growth) but also functions as a biostimulant. This dual role enhances the overall performance of crops in the field; however, the effectiveness can vary depending on several factors.

[0017] 1is a diagrammatic representation of the process steps for production of improved sulfur bentonite fertilizer composition with potassium fulvate.

[0018] shows a representative image of the improved sulfur bentonite fertilizer composition with potassium fulvate.

[0019] In explaining the embodiments of the invention, specific terms have been selected for clarity. However, the intention is not to restrict the invention to these terms; each term encompasses all technical equivalents that function similarly to achieve a comparable objective.

[0020] Pastille granules are a formulation composed of granules derived from a molten mixture. These granules can be applied to soil using basal and top-dress application methods. Once exposed to moisture or water in the soil, they break down and disperse effectively.

[0021] In another embodiment, the invention describes a method for producing an enhanced sulfur bentonite fertilizer composition that incorporates a biostimulant property. This composition includes potassium fulvate, preferably in powdered form, molten elemental sulfur, and at least one clay-based carrier or dispersible agent, ideally sodium bentonite clay.

[0022] In another embodiment, various types of humate-fortified fertilizers, including potassium humate, sodium humate, and potassium fulvate, are available on the market to provide additional benefits such as biostimulants and improved soil conditions, addressing the needs of modern agriculture. While sulfur-bentonite enriched with potassium humate is utilized in agriculture, these fertilizers do not exhibit effective biostimulant effects due to their large molecular weight.

[0023] In one embodiment, a solution to enhance the existing sulfur bentonite fertilizer composition by incorporating potassium fulvate. This improvement addresses the limitations of current potassium humate-based sulfur bentonite fertilizers, ensuring effective biostimulant properties and overall performance in both acidic and alkaline soils, including saline and alkaline irrigated soils.

[0024] In another embodiment, the disclosed composition preferably includes a potassium-chelated form of fulvic acids; however, other forms are also within the scope of this invention. Additionally, it is well-known that fulvic acid salts or combination products (organo-mineral fertilizers) generally outperform standard fertilizers.

[0025] In one embodiment, the improved sulfur-bentonite pastille fertilizer compositions are enhanced by the addition of potassium fulvate. This compound not only aids in the oxidation of elemental sulfur but also acts as a chelating agent that binds essential nutrients such as potassium, calcium, magnesium, and trace elements, thereby facilitating their absorption by plant roots.

[0026] In another embodiment, the described process yields an enhanced sulfur-bentonite fertilizer composition that incorporates potassium and fulvic acid derived from a single source of potassium fulvate. These compositions guarantee an effective supply of potassium along with low molecular weight fulvic acid molecules.

[0027] In one embodiment, potassium fulvate is the preferred source of potassium and fulvic acid; however, other related materials, such as sodium fulvate, calcium fulvate, magnesium fulvate, zinc fulvate, copper fulvate, iron fulvate and any form fulvic acids, can also be utilized in the disclosed process and is not depart from the scope of present invention.

[0028] In one embodiment, these fulvate salts may demonstrate enhanced biostimulant and agronomic performance when combined with sulfur-bentonite fertilizer.

[0029] In one embodiment, the composition may have a pH range of 6.0 to 8.5, which is optimal for the release of fulvic acid across the entire pH scale of soils. The release pattern of potassium fulvate molecules from the dispersed sulfur-bentonite pastille in the soil can modulate the physicochemical properties, thereby enhancing the mobilization and uptake of nutrients and improving plant physiology.

[0030] In one embodiment, after the release of potassium fulvate molecules, the oxidation of elemental sulfur will subsequently occur due to enhanced microbial activity. This underscores the multiple benefits of the composition's formulation for agricultural applications.

[0031] In one embodiment, the invention describes a process for producing sulfur-bentonite fertilizer compositions enhanced with potassium humate in pastille form, utilizing a molten mixture on a roto-form.

[0032] In one embodiment, elemental sulfur comprises 70 to 90 weight percent of the total composition, with a preferred range of 75 to 85 weight percent.

[0033] In one embodiment, potassium fulvate or any grade of fulvic acid is included in the composition at a weight percentage ranging from 1 to 20 weight percent, with an optimal range of 3 to 15 weight percent.

[0034] In another embodiment, sodium bentonite clay is included in the composition at a weight percentage ranging from 5 to 15 weight percent, with an optimal range of 7 to 13 weight percent.

[0035] In another embodiment, the particle size of potassium fulvate powder ranges from 0.1 to 100 microns, with a preference for sizes below 100 microns.

[0036] In a different embodiment, sulfur is present in a molten form, and the average particle size of the active components, whether in free, complex, or composite forms, ranges from 0.1 to 250 microns, ideally between 0.1 to 200 microns.

[0037] In one embodiment, the composition includes elemental sulfur, preferably potassium fulvate, and sodium bentonite clay, which is formed into pastilles measuring between 1to 5 mm, preferably from 2 to 4 mm.

[0038] In another embodiment, pastilles sized between 1 to 5 mm consist of individual molecules and composite particles ranging from 0.1 to 200 microns. These pastilles are formed by agglomerating or creating composite particles during the mixing and pastillation of a molten mixture under rapid cooling conditions.

[0039] In one embodiment, the potassium fulvate improved composition of sulfur bentonite fertilizer can be applied to soil using basal and topdressing techniques, or any other application method.

[0040] In another embodiment, the moisture content in the finished pastille form of the product is within the range of 0.3 to 1 weight percent, with a preferred range of 0.4 to 0.5 weight percent.

[0041] In one embodiment, the proportions of molten sulfur, bentonite, and sodium humate are determined based on their viscosity, ensuring that the mixture remains pumpable in its molten state to produce pastilles using a roto-form pastillator.

[0042] In one embodiment of this invention, elemental sulfur, bentonite, and potassium fulvate are mixed at atmospheric pressure within a temperature range of 130 to 140°C. During this process, sodium bentonite clay and potassium fulvate particles are typically dispersed or suspended in the molten sulfur medium.

[0043] In one embodiment, the molten sulfur mixture, referred to as the medium, contains both potassium fulvate and dispersed bentonite clay particles.

[0044] In another embodiment, the potassium fulvate particles are effectively maintained in the dispersion phase by adding sodium bentonite clay, resulting in a mixture that can be pumped and subjected to the pastillation process.

[0045] In a specific embodiment of this invention, elemental sulfur is utilized in its molten form, with the temperature maintained between 135 to 140°C.

[0046] In one embodiment, bentonite clay acts as an effective dispersant when combined with sulfur in a molten state. Sodium bentonite clay is added to the molten sulfur prior to the introduction of potassium fulvate powder, and the temperature is consistently maintained between 135 to 140°C throughout the preparation process. The heated molten mixture is then pumped and processed through roto-form pastillation to produce fertilizer pastilles.

[0047] In one embodiment, the disclosed production process for the potassium fulvate improved sulfur bentonite composition includes the following steps; however, the process may consist of fewer or additional steps depending on the scope of the present invention.

[0048] In one embodiment, high-purity molten sulfur is stored in a pit or tank and maintained at a weight percentage between 70 to 90 percent, with the temperature kept between 130 to 140°C.

[0049] In one embodiment, 5 to 15 weight percent of sodium bentonite clay is mixed into molten sulfur to form sulfur-bentonite mixture. This mixture is stirred for 5 to 10 hours at 40 RPM and a temperature of 135°C. These conditions promote the dispersion of the clay throughout the molten sulfur, resulting in a homogeneous sulfur-bentonite mixture.

[0050] In one embodiment, potassium fulvate or any grade of fulvic acid powder with a particle size of less than 100 microns, comprising 1 to 20 weight percent, is added to the molten sulfur-bentonite mixture. This mixture is then stirred for 3 to 6 hours or longer at 40 RPM and 135°C, allowing the potassium fulvate particles to be well dispersed in the molten sulfur-bentonite medium, forming a sulfur-bentonite-potassium fulvate molten mix.

[0051] In one embodiment, a molten mixture of sulfur, bentonite, and potassium fulvate is pumped onto a roto-form pastillator to produce pastilles of an improved sulfur-bentonite fertilizer composition. The resulting enriched pastille fertilizer contains sulfur-bentonite compositions with a substantial amount of sulfur-bentonite-boron mineral material complex.Examples

[0052] The disclosed inventive process describes the following example compositions for further clarification:

[0053] Example 1. (75S+10FA)IngredientsQuantity (Kg) required to produce one metric ton productElemental sulfur (99.9 percent pure in molten form)750 KgSodium bentonite clay125 KgPotassium fulvate (80 percent fulvic acid)25Kg

[0054] Example 2. (90S+2FA)IngredientsQuantity (Kg) required to produce one metric ton productElemental sulfur (99.9 pure in molten form)900 KgSodium bentonite clay78 KgFulvic acid (90 percent)22Kg

[0055] Example 3. (85S+4FA)IngredientsQuantity (Kg) required to produce one metric ton productElemental sulfur (99.9 pure in molten form)850 KgSodium bentonite clay100 KgPotassium fulvate (80 percent fulvic acid)50 Kg

[0056] Example 4. (80S+5FA)IngredientsQuantity (Kg) required to produce one metric ton productElemental sulfur (99.9 pure in molten form)800 KgSodium bentonite clay128 KgPotassium fulvate (70 percent fulvic acid)72 Kg

Claims

In this invention, a process for producing an improved sulfur-bentonite fertilizer composition, incorporating potassium fulvate disclosed.In the first step, 70 to 90 weight percent molten sulfur added to a tank or pit, and the temperature maintained between 130 to 140 °C.In the second step, the temperature of the molten sulfur maintained between 130 to 140 °C. Sodium bentonite clay, comprising 5 to 15 weight percent, mixed with the molten sulfur from the first step. This process produces a sulfur-bentonite mixture, which stirred for 5 to 10 hours at 40 RPM and 135 °C, these conditions facilitate the even dispersion of the clay throughout the molten sulfur, resulting in a homogeneous sulfur-bentonite mixture.In the third step, potassium fulvate or any grade of fulvic acid powder, with a particle size of less than 100 microns and comprising 1 to 20 weight percent, is added to the sulfur-bentonite mixture from the second step, mixture stirred for 3 to 6 hours at 40 RPM and a temperature of 135 °C, allowing the potassium fulvate particles to disperse into the molten sulfur-bentonite medium, resulting in a sulfur-bentonite-potassium fulvate mix.In the fourth step, the sulfur-bentonite-potassium fulvate mixture from the third stage pumped into a roto-form pastillator to produce the desired fertilizer compositions.An improved sulfur-bentonite fertilizer composition containing potassium fulvate, as described in claim 1, wherein the molten sulfur, with a purity of 99.9 percent, is incorporated in an amount ranging from 70 to 90 weight percent.An improved sulfur-bentonite fertilizer composition containing potassium fulvate, as described in claim 1, wherein the sodium bentonite clay is incorporated in an amount ranging from 5 to 15 weight percent.An improved sulfur-bentonite fertilizer composition containing potassium fulvate, as described in claim 1, wherein the potassium fulvate or any grade of fulvic acid is incorporated in an amount ranging from 1 to 20 weight percent.An improved sulfur-bentonite fertilizer composition containing potassium fulvate, as described in claim 1, in which the particle size of the potassium fulvate powder is less than 100 microns.An improved sulfur-bentonite fertilizer composition containing potassium fulvate, as described in claim 1, wherein the pastillation performs at a temperature range of 130°C to 135°C in the roto form to produce the disclosed composition.

7. An improved sulfur-bentonite fertilizer composition containing potassium fulvate, as disclosed in claim 1, wherein the composition is formed into pastilles that are approximately 1 to 5 mm in diameter.

8. An improved sulfur-bentonite fertilizer containing potassium fulvate, as described in claim 1, is designed for agricultural applications as both a fertilizer and a soil conditioner.

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