Urea Ammonium Nitrate Blend Stability via Polymer Mediator
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Solution Overview
Problem
Urea and ammonium nitrate are incompatible in solid blends due to the formation of hygroscopic double salts, leading to caking and mud formation, making it difficult to produce stable and safe high-concentration nitrogen fertilizers.
Innovation Solution
A solid blend of urea and ammonium nitrate particles is created by incorporating ammonium sulphate and a desiccant like magnesium nitrate, ensuring compatibility and preventing the formation of unwanted double salts, with particles of similar size and density to maintain stability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If urea and ammonium nitrate are blended in solid form, then high nitrogen concentration is achieved, but double salt formation occurs leading to caking and mud formation
Solution Approach 1:
A water-soluble polymer is introduced as an intermediary substance between urea and ammonium nitrate particles. The polymer absorbs the water released during double salt formation, preventing the liquid phase from causing caking and mud formation, thereby enabling stable high-concentration blends
Solution Approach 2:
The invention changes the physical-chemical parameters of the blend by adding a polymer with specific molecular weight and hydroxyl number. This modifies the water binding capacity of the system, allowing the blend to maintain stability at high nitrogen concentrations that would otherwise be unstable
2Quantity of substance
If urea and ammonium nitrate are blended, then nitrogen fertilizer efficiency is improved, but hygroscopicity increases causing water absorption from atmosphere
Solution Approach 1:
The water-soluble polymer acts as a mediator that selectively binds water molecules released during double salt formation and water absorbed from the atmosphere, preventing these water molecules from causing caking and reducing overall hygroscopicity of the blend
Solution Approach 2:
The invention creates a composite fertilizer blend consisting of urea particles, ammonium nitrate particles, and water-soluble polymer. This composite structure combines the high nitrogen content benefits of both fertilizers while the polymer component counteracts the hygroscopicity issue
3Stability of the object's composition
If double salt formation is prevented, then blend stability is improved, but manufacturing complexity increases
Solution Approach 1:
The water-soluble polymer is added during the existing granulation or blending process, requiring minimal equipment modification. The polymer is distributed throughout the blend using standard mixing equipment, maintaining manufacturing simplicity while achieving blend stability
Solution Approach 2:
The manufacturing process parameters are adjusted by incorporating the polymer at specific stages (granulation or blending) with controlled amounts based on the fertilizer composition. These parameter changes are integrated into existing processes without requiring complex new equipment
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 allows for the production of a stable, safe, and highly concentrated nitrogen fertilizer that is resistant to caking and misuse, with limited adaptations to existing production processes, ensuring safety and economic viability.
Implementation Method 1
The ammonium nitrate based particles comprise a salt that is able to bind crystallisation water, selected from magnesium nitrate, magnesium sulphate, aluminium sulphate or mixtures thereof
Implementation Method 2
The urea based particles contain ammonium sulphate, either in the mass of the particle (for instance distributed throughout the particle) or as an external layer
Data Source
AI summary
The present invention relates to a solid blend of urea based and ammonium nitrate based particles, the blend comprising ammonium nitrate based particles with salts able to bind crystallization water and urea particles with ammonium sulphate.