Molten Urea Stabilizer Integration to Reduce Biuret and Ammonia Loss
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Solution Overview
Problem
Current nitrogen fertilizer compositions face issues with nitrogen loss due to rapid hydrolysis of urea in soil, high moisture content, biuret formation, and handling difficulties of nitrogen stabilizers like NBPT and DCD, which affect efficacy and safety.
Innovation Solution
A urea-nitrogen stabilizer composition is developed where nitrogen stabilizers are incorporated directly into molten urea with reduced water and impurity content, using less N-methyl pyrrolidone (NMP) and minimizing biuret formation, and incorporating nitrification inhibitors to enhance nitrogen retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If nitrogen stabilizers are coated on granular urea or added to aqueous solutions, then nitrogen retention is improved, but handling difficulties and residual dust problems occur
Solution Approach 1:
The patent combines the nitrogen stabilizer incorporation step with the urea granulation process itself. The stabilizers are added to molten urea during manufacturing, so the stabilizer and urea are merged into a single homogeneous granule formation process, eliminating separate coating steps and handling issues
Solution Approach 2:
The patent uses molten urea as an intermediary medium to incorporate nitrogen stabilizers. The stabilizers are dissolved or dispersed in the molten urea before granulation, allowing uniform distribution without requiring separate coating carriers that cause dust problems
2Reliability
If granular urea is coated with nitrogen stabilizers using liquid carriers, then nitrogen loss is reduced, but hygroscopicity and handling problems increase
Solution Approach 1:
The patent extracts the liquid carrier component from the nitrogen stabilizer application process. By incorporating stabilizers directly into molten urea without hygroscopic liquid carriers, the patent eliminates the source of hygroscopicity while maintaining nitrogen loss reduction benefits
Solution Approach 2:
The patent changes the physical state parameter of urea from solid granules to molten liquid during the stabilizer incorporation step. This parameter change allows direct mixing and dissolution of stabilizers without requiring external liquid carriers, thereby reducing hygroscopicity
3Ease of operation
If nitrogen stabilizers are incorporated into molten urea, then handling is improved, but biuret formation increases and purity decreases
Solution Approach 1:
The patent performs preliminary action by incorporating nitrogen stabilizers into molten urea before the granulation and cooling steps. This timing allows uniform distribution while minimizing exposure time to temperatures that promote biuret formation, as the stabilizers are added early in the process flow
Solution Approach 2:
The patent rushes through the high-temperature molten urea stage by quickly incorporating stabilizers and proceeding to granulation and cooling. This minimizes the residence time at temperatures where biuret formation occurs, reducing unwanted byproduct accumulation
4Productivity
If urea is rapidly hydrolyzed in soil, then nitrogen availability to plants is improved, but ammonia volatilization increases and nitrogen loss occurs
Solution Approach 1:
The patent applies preliminary action by incorporating nitrogen stabilizers (urease inhibitors and nitrification inhibitors) into urea before application to soil. These stabilizers pre-establish protective mechanisms that control the hydrolysis rate, allowing nitrogen to be released gradually rather than rapidly, thus maintaining availability while preventing ammonia loss
Solution Approach 2:
The patent implements a feedback mechanism through the use of stabilizers that respond to soil conditions. The urease inhibitors feedback control the urea hydrolysis rate by inhibiting the urease enzyme, creating a self-regulating system that releases nitrogen at optimal rates based on soil moisture and microbial activity
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 solution effectively reduces ammonia volatilization, minimizes nitrogen loss, and improves handling and storage stability of nitrogen stabilizers, maintaining fertilizer efficacy while reducing environmental and regulatory concerns.
Implementation Method 1
Urea as a form of nitrogen is barely taken up, or not at all, as it is rapidly hydrolyzed in the soil by the enzyme urease. Urease is ubiquitious in soil bacteria and fungi and it converts the urea back into ammonia and carbon dioxide
Implementation Method 2
Urease inhibitors are compounds capable of temporarily inhibiting the catalytic activity of the urease enzyme on urea in moist soil. Slowing the urease-catalyzed transformation of urea to ammonium minimizes ammonia losses
Implementation Method 3
Nitrification inhibitors are compounds which inhibit the conversion of ammonium to nitrate and thus, also reduce nitrogen losses in the soil
Data Source
AI summary
This invention relates to an improved urea-nitrogen stabilizer composition and methods, systems and apparatti for making thereof. The nitrogen stabilizer composition is incorporated into molten urea to result in a composition that contains less biuret, NMP, nitrogen stabilizer and/or impurities and provides an effective solid fertilizer. These compositions are useful in in odor control.