Molten Methylene Urea Composition for Controlled Nitrogen Release
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Solution Overview
Problem
Conventional production of slow-release nitrogen compounds is energy-intensive, involves complex processes, and often results in undesirable ratios of desirable slow-release nitrogen compounds to cold-water insoluble nitrogen compounds.
Innovation Solution
A molten process is used to form fertilizer compositions by reacting urea and formaldehyde with a resin modifier, acid catalyst, and emulsifier, which controls the reaction temperature and composition to produce desirable ratios of methylenediurea (MDU) and dimethylenetriurea (DMTU) while minimizing cold-water insoluble nitrogen compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fertilizers are applied to crops, then nitrogen is available for plant growth, but volatile emissions into the atmosphere and groundwater contamination occur
Solution Approach 1:
The patent applies a polymer coating shell around nitrogen-containing fertilizer granules. This flexible shell controls the release of nitrogen by allowing it to pass through gradually over time, preventing volatile emissions into the atmosphere and reducing groundwater contamination while maintaining nitrogen availability for plant growth.
Solution Approach 2:
The polymer coating is designed with controlled porosity to regulate nitrogen release. The porous structure allows nitrogen to diffuse through the coating at a controlled rate, achieving slow-release functionality that reduces environmental harm while maintaining crop nutrition.
2Quantity of substance
If conventional fertilizers are applied, then crops receive nitrogen nutrients, but application frequency must be repeated multiple times
Solution Approach 1:
The polymer coating provides dynamic control over nitrogen release rates. The coating allows nitrogen to be released gradually over an extended period in response to environmental conditions, reducing the frequency of application while maintaining adequate nitrogen levels in the soil for crop growth.
Solution Approach 2:
The slow-release mechanism ensures continuous nitrogen availability to crops over an extended period. This continuous release pattern eliminates the need for repeated applications, as the fertilizer maintains effective nitrogen levels throughout the growth season.
3Object-generated harmful factors
If polymer coatings are applied to achieve slow-release, then environmental harm is reduced, but manufacturing complexity increases
Solution Approach 1:
The polymer coating process is designed to be self-regulating, where the coating material inherently controls nitrogen release through its physical and chemical properties. This self-service mechanism reduces the need for complex control systems and monitoring, simplifying the overall manufacturing process while maintaining environmental benefits.
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 process achieves a balanced release of nitrogen over weeks to months, with up to 50% of total nitrogen as MDU and DMTU, and low viscosity, facilitating easy application and granulation, and reducing crystallization rates.
Implementation Method 1
The polymer coating is designed to control the release of nitrogen from the fertilizer granule, allowing plants to absorb nutrients at a steady rate over an extended period
Implementation Method 2
The polymer coating degrades under specific environmental conditions, releasing nitrogen in a controlled manner
Implementation Method 3
The encapsulation process embeds nitrogen-containing compounds within a polymer matrix, enabling controlled release
Implementation Method 4
Ammonium-based fertilizers convert to nitrate through nitrification, a process carried out by soil bacteria
Data Source
Figure 1~2A
Figure 2B~3
Figure 4~5
AI summary
Methods of forming a fertilizer composition having slow-release nitrogen compounds with a molten process are disclosed. The methods include mixing of a polyethylene wax with urea, formaldehyde, and one or more of an acid catalyst and emulsifier to form a molten methylene urea mixture. The contents of the molten methylene urea mixture react to form slow-release nitrogen compounds. Fertilizer compositions formed of, or including, the slow-release nitrogen compounds are also disclosed.