Core-Shell Fertilizer Particles with Clay Shell

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Solution Overview

Problem

Existing fertilizer pellets face issues with sticky buildup in coating equipment and premature release of nutrients, necessitating a need for environmentally friendly slow-release coatings that maintain fertilizer concentration without adverse effects.

Innovation Solution

The development of core-shell composite particles, where a seed particle coated with a clay-based shell is formed through atomization and drying, followed by application of a biodegradable polymer coating to control the release of agricultural treatment materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If conventional coating methods are used to create slow-release fertilizer coatings, then nutrient release control is improved, but sticky buildup occurs in coating equipment

Engineering Contradiction:

Improvenutrient release controlVSAvoidcoating equipment operation

Core Design Contradiction:

Duration of action of moving objectVSEase of manufacture

Solution Approach 1:

The invention changes the physical and chemical parameters of the coating material by using calcium carbonate-based compositions with specific particle size distributions (D10, D50, D90 values) and moisture contents (10-50%). These parameter changes enable the coating to provide slow-release functionality while maintaining free-flowing properties that prevent sticky buildup in equipment

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses composite coating materials comprising calcium carbonate particles combined with binders and optional additives. This composite approach allows the coating to achieve both the slow-release function and the mechanical properties needed to prevent sticking, combining the benefits of different materials while minimizing drawbacks

Inventive Principle:

Principle #40Composite materials

2Duration of action of moving object

If slow-release coatings are applied to fertilizer pellets, then long-term fertilizer effectiveness is improved, but chemicals are released into the surrounding environment

Engineering Contradiction:

Improvefertilizer effectiveness durationVSAvoidchemical release into environment

Core Design Contradiction:

Duration of action of moving objectVSObject-generated harmful factors

Solution Approach 1:

The invention uses calcium carbonate, a naturally occurring substance, as the primary coating material and replaces synthetic slow-release chemicals. The particle size parameters and composition ratios are optimized to achieve controlled nutrient release without requiring harmful chemical additives, thus extending fertilizer effectiveness while minimizing environmental chemical release

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces complex, persistent chemical coatings with a simpler, naturally degradable calcium carbonate-based coating. This coating provides the necessary slow-release function during the fertilizer's effective period but breaks down harmlessly in the environment, avoiding long-term chemical contamination

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If coating thickness is increased to prevent premature nutrient release, then nutrient retention is improved, but fertilizer concentration in each pellet is reduced

Engineering Contradiction:

Improvenutrient retentionVSAvoidfertilizer concentration

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The invention optimizes the particle size distribution parameters (D10, D50, D90) of the calcium carbonate coating to achieve effective nutrient retention with minimal coating thickness. The specific size range allows the coating to form a protective barrier while maintaining high fertilizer concentration in the pellet core

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The calcium carbonate coating structure provides controlled porosity that allows selective permeation - retaining nutrients during storage and transport while permitting gradual release during the intended fertilization period. This porous structure achieves reliable nutrient retention without requiring excessive coating thickness that would dilute fertilizer concentration

Inventive Principle:

Principle #31Porous materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method prevents sticky buildup and ensures controlled, long-term release of nutrients, maintaining fertilizer concentration and reducing environmental impact.

Implementation Method 1

atomizing a slurry containing a clay into droplets

Methodology Applied

Scientific EffectAtomization:

Implementation Method 2

drying the green pellet to provide the composite particle

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS20240270662A1Core-shell composite particles and methods of making same

Publication Date: 2024.08.15 CARBO CERAMICS INC

AI summary

A composite particle is described herein. The composite particle can contain a seed particle of an agricultural treatment material and a shell disposed on the seed particle, wherein the shell comprises a clay.