Fluid Nitrogenous Phosphoryl Compositions for Low-Cost Fertilizer Blending
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Solution Overview
Problem
Current methods for producing nitrogenous phosphoryl compounds are costly due to the need for high-pressure equipment, hazardous solvents, and complex purification steps, making them unsuitable for large-scale industrial applications and limiting their use to high-cost substrates like urea.
Innovation Solution
A low-cost process that maintains nitrogenous phosphoryl compounds in a fluid state throughout production, avoiding volatile aprotic liquids, inorganic by-product removal, and solid purification steps, using aprotic organic liquids as reaction media to create ready-to-use fluid compositions that can be applied directly to substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If current methods are used to produce nitrogenous phosphoryl compounds, then high purity compounds are obtained, but the process cost increases due to high-pressure equipment, hazardous solvents, and complex purification steps
Solution Approach 1:
The patent extracts and eliminates the need for high-pressure equipment, hazardous solvents, and complex purification steps by using aqueous reaction conditions and simple filtration. This separates the essential function of producing pure compounds from the costly and hazardous process steps, achieving high purity without high manufacturing cost.
Solution Approach 2:
The patent changes the reaction parameters from high-pressure and non-aqueous conditions to ambient pressure and aqueous conditions. This parameter change simplifies the equipment requirements and eliminates hazardous solvents while maintaining product purity through controlled crystallization and filtration processes.
2Manufacturing precision
If current methods are used to produce nitrogenous phosphoryl compounds, then high purity compounds are obtained, but the process complexity increases due to multiple steps including solvent removal, purification, and formulation
Solution Approach 1:
The patent merges multiple separate process steps (reaction, filtration, crystallization, drying) into a single integrated aqueous process. The reaction occurs directly in water, products crystallize in situ, and impurities are removed by filtration, eliminating the need for separate solvent removal and purification steps.
Solution Approach 2:
The patent employs self-service mechanisms where the reaction medium itself (water) serves multiple functions: as the reaction medium, as the crystallization medium, and as the purification medium. The products self-crystallize from the aqueous solution, eliminating the need for external purification equipment and complex processing.
3Manufacturing precision
If nitrogenous phosphoryl compounds are produced as solids requiring purification, then high purity is achieved, but the products become temperature sensitive, sticky, and difficult to handle
Solution Approach 1:
The patent changes the physical state parameter of the product from solid to aqueous solution, eliminating the temperature sensitivity and stickiness associated with solid forms. The compounds remain dissolved in water during handling and application, improving ease of operation while maintaining purity through controlled crystallization only when needed.
4Productivity
If volatile aprotic liquids are used as reaction media, then the reactions proceed efficiently, but the process requires costly removal of the solvent and generates hazardous waste
Solution Approach 1:
The patent replaces expensive, hazardous volatile aprotic liquids with water, a cheap and non-hazardous solvent that can be easily disposed of or reused. Water serves as the reaction medium without requiring costly removal processes, eliminating solvent recovery infrastructure and reducing waste disposal costs.
Solution Approach 2:
The patent converts the typically harmful volatile aprotic solvents into beneficial aqueous conditions. Water, which is safe and inexpensive, provides the necessary reaction environment while eliminating the hazards and costs associated with volatile solvents, turning a potential harm into a benefit.
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
Enables the production of low-cost, ready-to-use fluid nitrogenous phosphoryl compositions suitable for simple blending with granular solids, reducing manufacturing costs and allowing widespread access to high-tech fertilizers, improving food production while minimizing environmental pollution.
Implementation Method 1
reacting phosphoryl trichloride and/or thiophosphoryl trichloride with one or more alkylamines utilizing a liquid reaction medium for the preparation of monoalkylamide phosphoryl dichlorides and/or monoalkylamide thiophosphoryl dichlorides
Implementation Method 2
maintains nitrogenous phosphoryl compounds in a fluid state throughout production
Data Source
AI summary
Methods are disclosed for the manufacture of nitrogenous phosphoryl compounds as fluid compositions utilizing a reaction medium comprising one or more aprotic organic liquids that are not reactive with one or more phosphoryl chlorides functional groups and optionally one or more non-aqueous organic liquids as processing aides that result in fluid products for delivering the resulting nitrogenous phosphoryl compounds to the surface of a substrate. Methods are disclosed that eliminate the need for one or more of the following: 1) purifying of one or more nitrogenous phosphoryl compounds, 2) stripping of volatile organic solvents, 3) removal of inorganic by-products, 4) generating solid nitrogenous phosphoryl compounds, 5) packaging one or more solid nitrogenous compounds, and 6) dissolving the solid nitrogenous phosphoryl compounds into a liquid delivery system for application to the surface of a substrate. Methods are disclosed that lower the overall manufacturing cost, wherein said fluid nitrogenous phosphoryl compositions comprise liquid solutions, fluid colloids, and fluid suspensions. Fluidized nitrogenous phosphoryl compounds are applied onto fertilizer solid surfaces using simple blending equipment that commingle the composition with solid granules allowing farmers and small co-ops access to high tech, state of the art fertilizers at lower cost.