Particulate Fertilizer Additive Integration Without Extra Equipment
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Solution Overview
Problem
Conventional methods for producing solid, particulate fertilizer compositions with additives like biostimulants and micronutrients require additional equipment, which is not always suitable and can increase costs.
Innovation Solution
Additives such as biostimulants and micronutrients are introduced into the fertilizer production process as an aqueous suspension, dispersion, solution, or solid at specific points, such as the effluent gas treatment unit or scrubber solution storage container, without affecting the final product quality and reducing the need for additional water removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If additives are added into the melt during concentration or before solidification using conventional methods, then the fertilizer composition can be produced with additives, but additional equipment is required and manufacturing costs increase
Solution Approach 1:
The patent combines the additive addition step with the existing melt concentration and solidification process. The additive is introduced into the melt during the concentration phase using the existing evaporator system, eliminating the need for separate addition equipment. This merging of operations reduces both device complexity and manufacturing costs while maintaining product quality.
Solution Approach 2:
The existing evaporator system is made multi-functional by using it not only for water removal during concentration but also for adding additives to the melt. This universal use of the evaporator for both concentration and additive incorporation eliminates the need for dedicated additive addition equipment, thereby reducing overall system complexity and operational costs.
2Quantity of substance
If additives are added to the melt, then the fertilizer composition contains the additive, but additional water removal is required which increases process complexity
Solution Approach 1:
The additive is introduced into the melt during the concentration phase, before the final solidification step. This preliminary addition allows the additive to be incorporated while the melt is still in a manageable state, and the existing water removal process continues uninterrupted. The additive is added at an optimal moment when the melt concentration is sufficient to ensure proper incorporation without requiring additional water removal steps.
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 allows for efficient production of solid, particulate fertilizer compositions with controlled additive content, reducing manufacturing costs and maintaining product quality by utilizing existing process steps to integrate additives effectively.
Implementation Method 1
in the evaporator unit, concentrating the aqueous solution produced in step (i), thereby obtaining a fertilizer melt comprising from 1.0 to 5.0 weight % of water
Implementation Method 2
in the particulation unit, particulating the melt obtained in step (ii), there-by obtaining a solid, particulate, fertilizer composition
Data Source
AI summary
A method for the manufacture of a solid, particulate, fertilizer composition including a nitrogen source selected from the group consisting of urea, and ammonium salts, and an additive selected from the group consisting of biostimulants and micronutrients, in a production plant including at least a synthesis unit, an evaporator unit, a particulation unit, an effluent gas treatment unit including a scrubber, and optionally a scrubber evaporator.