Modular Premix Batching System for On-Site Micronutrient Chelation
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Solution Overview
Problem
Current methods for applying micronutrients to crops are inefficient and costly, with foliar products being poorly absorbed and requiring dilute mixtures that incur high costs for packaging and delivery.
Innovation Solution
A modular premix batching and dispensing system that includes a skid-based batching and mixing system with dry bins for mineral sulfates and amino acids, a reactor for mixing and chelation reactions, and a dispensing network for precise application of mineral amino acid complexes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If foliar products are mixed in very dilute mixtures and shipped to the applicator, then packaging and delivery costs increase, but absorption effectiveness remains poor
Solution Approach 1:
The system performs preliminary mixing and formulation of concentrated micronutrient premixes at the application site just before use, rather than shipping pre-diluted products. This eliminates the need for costly packaging and delivery of large volumes of dilute solutions while ensuring the nutrients are in an optimized, absorbable form when applied to crops.
Solution Approach 2:
The invention changes the concentration parameter of the nutrient solution from very dilute (current practice) to concentrated premix form. By controlling the mixing ratio on-site, the system achieves both cost efficiency through reduced water volume and improved effectiveness through optimized nutrient concentration and chelation.
2Ease of operation
If broad spectrum products are used to address perceived nutrient deficiencies, then application simplicity is maintained, but assessment of total blend value becomes difficult
Solution Approach 1:
The system transitions from uniform broad-spectrum applications to localized, site-specific formulations. By testing soil and tissue samples at each location and mixing custom premixes tailored to specific deficiency profiles, the system optimizes nutrient delivery for each field's unique needs while maintaining operational simplicity through automated mixing equipment.
Solution Approach 2:
The invention segments the nutrient application process into discrete, controllable components. Instead of applying fixed broad-spectrum blends, the system separately dosing individual micronutrients based on specific deficiency assessments, allowing precise tracking of each nutrient's contribution to crop response.
3Productivity
If automated batching and mixing systems are implemented, then mixing efficiency improves, but system complexity increases
Solution Approach 1:
The system employs multi-functional equipment that performs multiple operations within a single integrated unit. The mixing apparatus combines weighing, mixing, chelation, and dispensing functions in one skid-mounted system, improving productivity while minimizing the number of separate components and reducing overall system complexity.
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 system enables efficient and cost-effective preparation and delivery of micronutrients, reducing waste and operational costs by automating the batching, mixing, and dispensing processes, and allowing for on-site production of specifically formulated premixes.
Implementation Method 1
a reactor having a mixing mechanism and being connected with the water source, the first dry bin, and the second dry bin and configured to accept quantities of water, dry mineral sulfate, and amino acid therefrom
Data Source
AI summary
A modular premix batching and dispensing system for crop micronutrient application includes a skid-based batching and mixing system with a first dry bin to store a dry mineral sulfate; a second dry bin to store an amino acid; a water source; a reactor having a mixing mechanism and connected with the water source and the dry bins; and a first controller configured to automatically control transfer of water, dry mineral sulfate, and amino acid to the reactor and to control operation of the reactor; and a skid-based day tank system with at least one day tank configured to store mineral amino acid complex received from the reactor; and a dispensing network configured to selectively transfer the mineral amino acid complex to an application receptable. An associated method of preparing and delivering micronutrients using a modular premix batching and dispensing system is also described.