Urea Additive Integration via Aqueous Scrubber Solution
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Solution Overview
Problem
The existing methods for adding urease inhibitors, nitrification inhibitors, and stabilizers to urea-based fertilizers often involve using organic solvents, which can lead to issues like toxic dust, high costs, and the introduction of alien chemicals into the soil, and do not allow for precise dosing during the urea production process.
Innovation Solution
Introducing these additives as an aqueous suspension, dispersion, or liquid into the urea melt during the production process, using the existing water in the urea plant's process steps to avoid solvent-related issues and ensure the additives are fully incorporated without affecting the urea quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If organic solvents are used to add urease inhibitors, nitrification inhibitors, and stabilizers to urea-based fertilizers, then the additives can be incorporated into the urea mixture, but toxic dust is generated, costs increase, and alien chemicals are introduced into the soil
Solution Approach 1:
The patent extracts and eliminates the organic solvent component from the addition process. Instead of using organic solvents to carry additives into the urea mixture, the invention uses water-based solutions or direct solid addition methods, thereby removing the source of toxic dust and alien chemical contamination while maintaining effective additive incorporation.
Solution Approach 2:
The patent replaces expensive organic solvents with water or direct solid addition methods. Water is cheaper, non-toxic, and leaves no harmful residues. The method allows for precise dosing of additives without the need for costly solvent systems, reducing both environmental harm and production costs.
2Ease of manufacture
If organic solvents are used to add additives to urea-based fertilizers, then the additives can be incorporated, but production costs increase
Solution Approach 1:
The patent replaces expensive organic solvents with water or direct solid addition methods. Water is significantly cheaper than organic solvents and does not require costly recovery or disposal processes. This substitution directly reduces production costs while maintaining effective additive incorporation through precise dosing capabilities.
3Measurement precision
If additives are added to urea melt, then precise dosing is achieved, but water content in the urea melt increases
Solution Approach 1:
The patent performs preliminary concentration of the urea melt to a high solid content (90-99%) before adding the aqueous additive solution. This preliminary action reduces the final water content in the urea product while still allowing precise dosing of the additive. The concentrated state enables accurate measurement and incorporation of small amounts of additive without excessive water dilution.
Solution Approach 2:
The patent changes the concentration parameter of the urea melt from typical lower concentrations to a highly concentrated state (90-99% urea). This parameter change allows water-based additive solutions to be added with minimal impact on the final water content, while still achieving precise dosing control. The high solid content provides a stable matrix for accurate additive incorporation.
4Object-affected harmful factors
If additives are added as aqueous suspension or dispersion, then alien substances are avoided, but the additives must be fully incorporated without affecting urea quality
Solution Approach 1:
The patent performs preliminary concentration of the urea melt before adding aqueous additive suspensions or dispersions. This preliminary concentration creates a stable, high-solid-content matrix that prevents water-based additives from negatively affecting urea quality. The concentrated state ensures complete incorporation of additives while maintaining urea crystal structure and chemical properties.
Solution Approach 2:
The patent changes the physical state and concentration parameters of the urea melt to a highly concentrated solid-like state (90-99% urea). This parameter change creates an environment where aqueous additives can be fully incorporated without dissolving or degrading the urea crystals. The high solid content provides structural stability that protects urea quality while allowing additive integration.
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
This method allows for precise dosing and effective incorporation of additives into the urea-based composition without introducing alien substances, reducing toxic dust and costs, and maintaining the chemical stability of the urea, thereby enhancing nitrogen availability and crop yields.
Implementation Method 1
treating the effluent gas from the particulation section comprising urea-based dust particles and ammonia gas with water to produce a scrubber solution
Implementation Method 2
in the evaporator section, concentrating a urea melt of about 80 weight%, to about 95 to 99 weight% of urea
Data Source
Figure 1
AI summary
A method is disclosed for the manufacture of a homogeneous, solid, particulate, urea- based composition comprising urea and one or more additives in a urea production plant comprising at least an evaporator section and a particulation section, further comprises one or more of a mixing section, an effluent gas treatment section and a scrubber solution storage section, wherein the method comprises at least the steps of: (i) in the evaporator section, concentrating a urea melt of about 80 weight% to about 95 to 99 weight% of urea; (ii) in the particulation section, particulating a urea or urea-based melt into a urea or urea- based composition; and further comprises one or more of the steps of: (iii) in the mixing section, if present, mixing the urea melt of about 95 to 99 weight% with other fertilizer components to produce a urea-based melt; (iv) in the effluent gas treatment section, if present, treating the effluent gas from the particu¬ lation section comprising urea-based dust particles and ammonia gas with water to produce a scrubber solution; and (v) in the scrubber solution storage section, if present, storing the scrubber solution from the effluent gas treatment section; wherein the additive is introduced into the urea or urea-based composition as an aqueous suspension, an aqueous dispersion, or an aqueous liquid, by adding the additive to one or more of: (a) said effluent gas treatment section, if present; (b) said scrubber solution storage section containing the scrubber solution, if present. (c) said urea melt of about 80 weight% upstream of the evaporation section. (d) said urea-based melt in the mixing section, if present;