Sodium humate-supplemented bentonite fertilizer composition and method of production

Abstract

The present invention relates to a sodium humate-supplemented sulfur-bentonite fertilizer composition and its production process. The fertilizer composition includes sodium humate (1 to 16 weight percent), elemental sulfur (75 to 90 weight percent), and a clay material (7 to 15 weight percent), typically sodium bentonite. The process for producing the composition involves heating molten sulfur, mixing it with sodium bentonite clay, and subsequently adding sodium humate powder with a particle size of less than 100 microns. The mixture is then stirred and pastillized using a roto-form pastillator at temperatures between 130°C to 135°C. The resulting fertilizer composition is suitable for agricultural use as both a fertilizer and soil conditioner and is suitable for both basal and top-dressing applications.

Description

Sodium Humate-Supplemented Bentonite Fertilizer Composition and Method of Production

[0001] This invention is in the field of agricultural fertilizers and soil amendments, with reference to sodium humate-supplemented bentonite fertilizer compositions and their method of production.

[0002] Humates are commonly used in agriculture as a fertilizer additive to increase the efficiency of fertilizers, especially nitrogen- and sulfur-based fertilizer inputs. Other salts of humic acid are manufactured, mainly sodium humate, which is used in animal health supplements.

[0003] The application of humates helps in improving soil health, plant growth and nutrient mobilization through the physical and biological processes. In agriculture potassium humates use is very common, but sodium humates are also gaining importance because of beneficial effect in certain crops, animal nutrition and on the potassium uptake ability of plants.

[0004] However, Various sodium containing biostimulants (sodium fulvates, and sodium humates) and fertilizers (Magnesia-Kainit, sodium nitrate, sodium sulphate etc.) have been successfully used for greatly increasing the sodium content and agronomic performance especially in certain root crops e.g. sugar beet, carrots, parsnips, and fodder crops.

[0005] Potassium (K+) is one of the three key nutrients that are essential for growing crops, alongside nitrogen and phosphate. While soil does provide potassium for plants, it often doesn't provide enough to meet the needs of crops. As a result, farmers need to add potassium fertilizers to ensure stable food production. Because of this necessity, the global use of potassium fertilizers has been increasing over time.

[0006] The statement highlights the importance of making potassium (K+) fertilizer more effective and minimizing the waste of both mineral and energy resources. This is crucial for two main reasons: it can lower the costs of farming and help protect the environment. The effectiveness of K+fertilizer depends on various factors, and the research being discussed specifically aims to enhance how well plants use this potassium fertilizer.

[0007] A phenomenon associated with sodium ions (Na+) explains that many chemical properties with potassium ions (K+), which allow Na+ to partially take the place of K+in plant cells. This means that the presence of Na+can influence how efficiently plants use K+. Although it is not yet completely confirmed, it is believed that Na+can act as a substitute for K+in helping to maintain the balance of water and salts within the vacuole, a storage space in plant cells.

[0008] Sodium is not necessary for most plants, and having too much of it in their cells can be harmful. However, a moderate level of sodium can be helpful for many crop species, especially when they are low on potassium. It is important to emphasize that every substance has a threshold below which it is not toxic.

[0009] Sodium shares some chemical properties with potassium and can sometimes take its place in plant cells. This means that sodium can play a role in how well plants use potassium.

[0010] Although we don't completely understand how sodium functions as an alternative nutrient, it's believed that sodium may help with the balance of water (osmotic pressure) in a part of the plant cell called the vacuole, like potassium does. Also, sodium can substitute for potassium in various metabolic processes, particularly in some C4 plants for CO2uptake.

[0011] Therefore, it is necessary to develop a sodium-enriched fertilizer composition that can be applied both through the soil and as a top-dressing. The most effective method for supplying sodium is through an organic material such as sodium salt of humic acid, more precisely, sodium humate, which can also serve as a plant biostimulant and soil conditioner.

[0012] Additionally, the inclusion of sodium humate into the sulfur bentonite may enhance the oxidation of elemental sulfur into a form usable by plants due to increased microbial activity in the soil. Thus, the present invention aims to create a process for producing sodium humate supplemented pastille-based sulfur bentonite fertilizers.

[0013] The disclosed invention provides a value-added sulfur-bentonite fertilizer composition, designed to effectively supply sodium, humic acid, and sulfur, thus supporting both crop nutrition and soil health. The composition comprises the following components:

[0014] Sodium humate: 1 to 16 weight percent,

[0015] Elemental sulfur: 75 to 90 weight percent,

[0016] Clay material (such as sodium bentonite): 7 to 15 weight percent.

[0017] The invention also discloses a process for producing the fertilizer composition in pastille form, supplemented with sodium humate, for both crop nutrition and soil health. The process includes the following steps:Molten sulfur is heated to a temperature of 130°C to 140°C and is used in an amount ranging from 75 to 90 weight percent.Sodium bentonite clay is added to the molten sulfur in an amount ranging from 7 to 15 weight percent, and the mixture is stirred at 135°C for 2 to 6 hours at a stirring speed of 40 RPM to form a uniform sulfur-bentonite mixture.Sodium humate powder, having a particle size of less than 100 microns and comprising 1 to 16 weight percent, is added to the sulfur-bentonite mixture. The mixture is stirred for 4 to 8 hours at 135°C at 40 RPM, resulting in a uniform sulfur-bentonite-sodium humate mixture.The resulting sulfur-bentonite-sodium humate mixture is then pumped into a roto-form pastillator at a temperature of 130°C to 135°C to form pastille-shaped fertilizer compositions.

[0018] The sodium humate used in the composition is typically the sodium salt of humic acid, which serves not only as a plant biostimulant but also as a soil conditioner. The presence of sodium humate enhances the oxidation of elemental sulfur, making it more bioavailable to plants. This is due to increased microbial activity in the soil, which improves the fertilizer's efficiency. The composition is suitable for both basal and top-dressing applications in agriculture.

[0019] The demand for more effective utilization of sulfur bentonite fertilizers, particularly in crop nutrition and soil health—has spurred the development of new formulations designed to enhance nutrient supply and mobilization, improve soil structure, and promote plant growth. Nevertheless, many current sulfur bentonite fertilizers that provide sulfur often fall short of meeting the expectations of growers and the requirements of crops, especially in areas with poor soil quality or specific crop needs.

[0020] Although humates, such as potassium humate, have been employed to enhance fertilizer efficiency, sodium humate-supplemented fertilizers have not been widely available or optimized to maximize both soil health and plant nutrition. Furthermore, a significant challenge remains in successfully combining sodium humate with sulphur-bentonite fertilizers production through roto form pastillation to enhance soil health, facilitate the oxidation of elemental sulfur, and supply sodium to plants.

[0021] The present invention addresses the technical problem by introducing a novel sodium humate-supplemented sulfur-bentonite fertilizer composition that improves both crop nutrition and soil health. This solution integrates sodium humate, elemental sulfur, and bentonite clay into a homogeneous fertilizer composition, which is then shaped into pastilles for convenient application in agricultural practices. The key features of the solution include:

[0022] Sodium humate as a biostimulant and soil Conditioner: Sodium humate, typically derived from the sodium salt of humic acid, acts as both a plant biostimulant and a soil conditioner. Its incorporation into the fertilizer composition enhances nutrient mobilization and supports microbial activity in the soil. Additionally, sodium humate can facilitate the oxidation of elemental sulfur, increasing its bioavailability to plants by boosting microbial activity in the soil. This process ensures that sulfur, an essential nutrient for plants, is readily available for uptake, particularly for crops that require sulfur for metabolic processes. It increases soil organic matter, improves water retention, and boosts microbial activity, thus fostering better soil structure and providing additional benefits beyond those of traditional sulfur bentonite fertilizers.

[0023] Improved potassium use efficiency: the composition utilizes the sodium component (from sodium humate) to enhance the efficiency of potassium uptake by plants. Sodium ions (Na+) possess similar chemical properties to potassium ions (K+), allowing sodium to partially substitute potassium in plant cells, especially in crops with higher potassium needs. This interaction aids plants in maintaining water balance (osmotic pressure) and supports metabolic processes, making the fertilizer particularly advantageous for crops such as sugar beet, carrots, and fodder crops.

[0024] Pastille form for efficient application: the invention encompasses a method for producing the fertilizer in pastille form, enhancing its handling, storage, and application. Utilizing a roto-form pastillator, the sulfur-bentonite-sodium humate mixture is shaped into uniform pastilles that can be easily applied to soil, either as a basal or top-dressing application. The pastille form allows for gradual fertilizer application, minimizing nutrient loss and improving fertilizer efficiency over time.

[0025] Efficient production process: this method guarantees an even distribution of the key components and the production of a stable, homogeneous fertilizer composition that can be efficiently applied to crops.

[0026] The key advantages of invention are as follows:Enhancing sulphur bentonite fertilizer value with sodium humate, especially for improving the soil health and crops needing sodium.Improving sulfur oxidation for better plant uptake.Optimizing a production process for sodium humate-supplemented sulfur-bentonite fertilizers in pastille form and ease of application

[0027] is a diagrammatic representation of the process steps for production of sodium humate supplemented bentonite fertilizer composition.

[0028] ]shows a representative image of the sodium humate supplemented bentonite fertilizer composition.

[0029] In explaining the embodiments of the invention, specific terms have been chosen for clarity. However, the intention is not to limit the invention to these terms; each term includes all technical equivalents that perform similarly to achieving a similar goal.

[0030] Pastille granules refer to a formulation made up of granules that can be applied using basal and top-dress methods after they break down and disperse when exposed to moisture or water in the soil.

[0031] The invention involves a method to produce the value-added sulfur bentonite fertilizer composition that contains sodium humate, preferably in powdered form, molten elemental sulfur, and at least one clay-based carrier or dispersible agent, ideally sodium bentonite clay. Furthermore, the particle size of sodium humate ranges from 0.1 to 100 microns.

[0032] In another embodiment, various types of sodium and humate-based fertilizers available on the market meet the sodium and humic needs of agriculture. While sulfur-bentonite enriched with potassium humate is used in agriculture, these fertilizers do not provide sufficient sodium for soil nutrient mobilization and certain crop needs.

[0033] We have developed a solution to enhance the existing sulfur bentonite fertilizer composition with an eco-friendly material, ensuring effective and safe sodium and humic fertilization by addressing various factors that affect sodium availability. In the disclosed composition, a sodium chelated form of humic acids is included, as it is well-known that humic acid salts or combination products generally exhibit higher efficiency than standard fertilizer salts.

[0034] In one embodiment, the enhancement of sulfur-bentonite pastille fertilizer compositions is achieved through the addition of sodium humate materials. Furthermore, sodium humate aids in the oxidation of elemental sulfur.

[0035] In another embodiment, the described process yields a value-added sulfur-bentonite fertilizer composition that includes sodium and humic acid derived from a single sodium humate source. This method ensures an effective supply of sodium and humic acid in slow-release manner, and minimizes the chances of the potential toxicity, which is very commonly linked to sodium fertilizers based on inorganic salts.

[0036] In one embodiment, sodium humate is the preferred source of sodium and humic acid; however, other related materials such as sodium fulvate, sodium alginate, sodium acetate, and sodium benzoate can also be used in the process.

[0037] In one embodiment, these sodium salts may exhibit improved agronomic performance when combined with sulfur-bentonite fertilizer.

[0038] In one embodiment, the composition may have a pH range of 7.0 to 9.5, as optimal release occurs when the soil pH above 7.0. This indicates that the sodium humate released from the dispersed sulfur-bentonite pastille in the soil can help mobilize nutrients by modulating cation exchange capacity or charge balance.

[0039] In one embodiment, after a few days of application, the oxidation of elemental sulfur will effectively commence due to increased microbial activity, particularly sulfur-oxidizing microbes. This highlights the dual functionality of the composition for agricultural applications.

[0040] In one embodiment, the invention presents a method to produce sodium humate-enhanced sulfur-bentonite fertilizer compositions in pastille form using a roto-form pastillation technique.

[0041] In one embodiment, elemental sulfur constitutes 75 to 90 percent of the total composition, with a preferred range of 80 to 90 weight percent.

[0042] In one embodiment, sodium humate is included in the composition at a weight percentage ranging from 1 to 16 weight percent, with an optimal range of 5 to 13 weight percent.

[0043] In another embodiment, the particle size of sodium humate powder is between 0.1 to 100 microns, with a preference for sizes below 100 microns.

[0044] In a different embodiment, sulfur is present in a liquid form, such as molten sulfur. The average particle size of the overall composition is between 0.1 to 250 microns, ideally from 0.1 to 200 microns.

[0045] In one embodiment, the composition includes elemental sulfur, sodium humate, and sodium bentonite clay, which is formed into pastilles that measure between 1 to 5 mm, preferably from 2 to 4 mm.

[0046] In another embodiment, pastilles sized between 1 to 5 mm consist of individual composite particles ranging from 0.1 to 200 microns. These pastilles are formed by agglomerating active particles during mixing and pastillation under heat and cooling conditions.

[0047] In one embodiment, the sodium humate supplemented composition sulfur bentonite fertilizer can be applied to soil using basal and topdressing techniques.

[0048] In another embodiment, materials with low moisture content are preferred for the process. Ideally, the moisture content in the mixture should be reduced through prolonged mixing at 135°C, targeting a range of 0.3 to 1 weight percent of the total mixture, with a preferred range of 0.4 to 1 weight percent.

[0049] In one embodiment, the proportions of molten sulfur, bentonite, and sodium humate are carefully calibrated to create a pumpable liquid medium suitable for roto form pastillation.

[0050] In one embodiment of this invention, molten sulfur, bentonite, and sodium humate are mixed at atmospheric pressure within a temperature range of 130 to 140°C, during which sodium bentonite clay and fine sodium humate particles are typically dispersed or suspended in the molten sulfur medium.

[0051] In one embodiment, it is desirable for the molten sulfur medium to include sodium humate particles that are dispersed and mixed with sodium bentonite clay. The molten sulfur, referred to as the medium, contains both the sodium humate particles and the dispersed bentonite clay.

[0052] In another embodiment, the sodium humate particles are effectively kept in the dispersion phase by adding sodium bentonite clay, resulting in a mixture that can be pumped.

[0053] In a specific embodiment of this invention, elemental sulfur is utilized in its molten form, with the temperature maintained between 135 to 140°C.

[0054] In one embodiment, bentonite clay serves as an efficient dispersant when combined with sulfur in a molten state, along with sodium humate particles. Sodium bentonite clay is added to the molten sulfur before introducing the sodium humate powder, and the temperature is consistently kept between 135 to 140°C throughout the preparation. The heated mixture is then pumped and processed through roto-form pastillation to create fertilizer pastilles.

[0055] In one embodiment, the production process includes one or more of the steps described below.

[0056] In one embodiment, high-purity molten sulfur (99.9 percent) is obtained and stored in a pit or tank. The composition is maintained at a weight percent between 75 to 90 percent, with the temperature kept between 130 to 140°C.

[0057] In one embodiment, sodium bentonite clay, making up 7 to 15 weight percent, is mixed into molten sulfur. This creates a sulfur-bentonite mixture that is stirred for 2 to 6 hours at 40 RPM and 135°C. These conditions facilitate the dispersion of the clay throughout the molten sulfur, resulting in a consistent sulfur-bentonite mixture.

[0058] In one embodiment, sodium humate powder with a particle size of less than 100 microns, comprising 1 to 16 weight percent, is added to the sulfur-bentonite mixture. This mixture is then stirred for 4 to 8 hours or longer at 40 RPM and 135°C, allowing the sodium humate particles to disperse into the molten sulfur-bentonite medium, forming a sulfur-bentonite-sodium humate complex.

[0059] In one embodiment, the sulfur-bentonite-sodium humate mixture is pumped onto a roto-form pastillator to create fertilizer compositions that result in a value-added sulfur-bentonite fertilizer product.Examples

[0060] The described inventive process describes the following example compositions for further clarification

[0061] Example 1. (75S+10HA)IngredientsQuantity (Kg) required to produce one metric ton productElemental sulfur (99.9 percent pure in molten form)750 KgSodium bentonite clay83 KgSodium humate (65 percent humic acid content)167Kg

[0062] Example 2. (90S+1HA)IngredientsQuantity (Kg) required to produce one metric ton productElemental sulfur (99.9 pure in molten form)900 KgSodium bentonite clay84.5 KgSodium humate (65 percent humic acid content)15.5Kg

[0063] Example 3. (85S+2HA)IngredientsQuantity (Kg) required to produce one metric ton productElemental sulfur (99.9 pure in molten form)850 KgSodium bentonite clay116.5 KgSodium humate (65 percent humic acid content)33.5 Kg

[0064] Example 4. (80S+5HA)IngredientsQuantity (Kg) required to produce one metric ton productElemental sulfur (99.9 pure in molten form)800 KgSodium bentonite clay120 KgSodium humate (65 percent humic acid content)77 Kg

[0065] The sodium humate-supplemented sulfur-bentonite fertilizer composition and its production process outlined in this invention hold considerable industrial relevance in agriculture and fertilizer manufacturing sectors. This innovative combination of sodium humate, elemental sulfur, and bentonite clay in pastille form effectively tackles essential challenges linked to conventional sulfur-bentonite fertilizers, including nutrient supply and mobilization, soil health, and crop productivity, thereby making it ideal for extensive commercial application

Claims

A sodium humate-supplemented sulfur-bentonite fertilizer composition, comprising:Sodium humate: 1 to 16 weight percent,Elemental sulfur: 75 to 90 weight percent,Bentonite clay: 7 to 15 weight percent, wherein the composition is in pastille form for application to soil.The composition of claim 1, wherein the sodium humate is the sodium salt of humic acid, which serves as both a biostimulant and a soil conditioner.A method for producing the sodium humate-supplemented sulfur-bentonite fertilizer composition of claim 1, comprising the steps of:Molten sulfur to a temperature of 130°C to 140°C and maintaining it in an amount of 75 to 90 weight percent;Mixing sodium bentonite clay in an amount ranging from 7 to 15 weight percent with the molten sulfur, and stirring the mixture at 135°C for 2 to 6 hours at 40 RPM to form a sulfur-bentonite mixture;Adding sodium humate powder having a particle size of less than 100 microns and comprising 1 to 16 weight percent to the sulfur-bentonite mixture, and stirring the resulting mixture for 4 to 8 hours at 135°C at 40 RPM to form a uniform sulfur-bentonite-sodium humate mixture;Pumping the sulfur-bentonite-sodium humate mixture into a roto-form pastillator at a temperature of 130°C to 135°C to form pastille-shaped fertilizer compositions.The method of claim 3, wherein the pastilles formed are suitable for both basal and top-dressing applications in agriculture.The method of claim 3, wherein the pastille-shaped fertilizer compositions improve potassium efficiency in crops by utilizing sodium ions (Na+) to partially substitute for potassium ions (K+) in plant cells.The composition of claim 1, wherein fertilizer enhances microbial activity in the soil, thereby improving soil health and increasing nutrient uptake by plants.The composition of claim 1, wherein the pastille form ensures a controlled release of nutrients over time, reducing the risk of nutrient leaching and improving fertilizer efficiency.The use of the fertilizer composition of claim 1 as a plant biostimulant, soil conditioner, or fertilizer to enhance crop nutrition, improve soil health, and promote efficient nutrient uptake, particularly for crops requiring sodium, and sulfur content.The use of the fertilizer composition of claim 1 for increasing the oxidation of elemental sulfur and enhancing its bioavailability to plants through increased microbial activity in the soil.

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