High-Load Agrochemical Formulations Using Shear-Thinning Flow
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Solution Overview
Problem
Existing agrochemical formulations face challenges in maintaining high concentrations of active agents with suitable viscosities and flowability while preventing settling, phase separation, and agglomeration during storage and application.
Innovation Solution
The formulation process involves bead or colloid milling to achieve particle sizes of 1-75 microns, combining agrochemical active agents with surfactants and thickening agents to create a shear thinning gel that transitions to a flowable fluid for application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high concentrations of active agents (57-76% w/w) are incorporated into the formulation, then the quantity of substance and productivity are improved, but the formulation becomes difficult to pump and apply due to increased viscosity and reduced flowability
Solution Approach 1:
The formulation utilizes shear-thinning behavior where the viscosity dynamically changes based on applied shear stress. At rest (storage conditions), the formulation maintains high viscosity to prevent settling. During pumping and application, shear force reduces viscosity temporarily, enabling easy flow. After application, viscosity returns to high state. This dynamic property resolves the contradiction between high concentration and flowability.
Solution Approach 2:
The formulation changes its rheological parameters (viscosity, flow behavior) in response to external conditions. The thickening agent concentration and particle size distribution are optimized to achieve shear-thinning behavior, allowing the same formulation to exhibit different flow characteristics under different conditions (storage vs. application), thus resolving the contradiction.
2Ease of operation
If the formulation remains in a flowable form during storage, then ease of operation is improved, but the solid particles settle and form hard pack sediment, worsening reliability
Solution Approach 1:
The formulation maintains high viscosity under static storage conditions to prevent particle settling, while being capable of transitioning to low viscosity under shear stress during application. This dynamic viscosity control ensures both storage stability and operational ease at different times.
Solution Approach 2:
The thickening agents and dispersants are pre-incorporated into the formulation at optimal concentrations to establish a stable dispersed structure before storage begins. This preliminary structuring prevents settling during storage, while the formulation retains the ability to flow when shear force is applied.
3Reliability
If structuring agents and thickening agents are added to prevent settling, then reliability is improved, but the viscosity increases and flowability during application deteriorates
Solution Approach 1:
The selection and combination of thickening agents (clays, celluloses, polyacrylates, xanthan gum) creates a formulation that exhibits shear-thinning behavior. The structuring agents provide viscosity at rest for stability, but the overall formulation viscosity drops under shear stress during application, resolving the contradiction between storage stability and flowability.
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
The method ensures stable dispersion of agrochemicals, preventing settling and allowing for easy application by maintaining a flowable form when needed, enhancing storage stability and application efficiency.
Implementation Method 1
bead milling the first homogenized mixture to form first particles having a D90 particle size of about 1-75 microns; or colloid milling the first homogenized mixture to form first particles having a D50 particles size of about 1-75 microns
Implementation Method 2
homogenizing a third mixture comprising an aqueous surfactant solution and a thickening agent to form a slurry
Implementation Method 3
wherein, the first mixture comprises 20-70% (w/w) of the at least one agrochemical active agent with the balance including water and optionally a surfactant, an antifreeze, a biocide, an antifoaming agent, or a combination thereof
Implementation Method 4
SC formulations may therefore typically comprise a solid active, surfactant, density/viscosity modifier system, freeze/thaw additive, bactericide, anti-foamer, and water diluent
Implementation Method 5
converting the dense phase slurry to a fluidized state, thereby forming the fluidized slurry
Data Source
AI summary
Provided are methods of forming agrochemical formulations including (a) homogenizing a first mixture comprising at least one agrochemical active agent in water to form a first homogenized mixture; (b) forming a first mill base by milling the first homogenized mixture; (c) homogenizing a second mixture comprising at least one agrochemical active agent and the first mill base to form a second homogenized mixture; (d) bead milling the second homogenized mixture; (e) homogenizing a third mixture comprising an aqueous surfactant solution and a thickening agent to form a slurry; and (f) combining the slurry with the second mill base to form an agrochemical formulation comprising 57-76% (w/w) of the agrochemical active agent, based on the total weight of the formulation.