VTAE Fertilizer Coating Dust Control
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Solution Overview
Problem
Fertilizers tend to generate dust and cake during storage and handling, posing safety, health, and environmental concerns, and existing solutions like oils and waxes have limitations in long-term dust control and anti-caking effectiveness.
Innovation Solution
A coating composition using vacuum tower asphalt extender (VTAE), which is a non-distilled fraction of re-refined automotive and industrial oils, is applied to fertilizers to reduce dust formation and caking, potentially combined with bitumen or asphalt, and emulsified with water for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If oil or wax is used to coat fertilizer particles, then dust formation is reduced initially, but the coating loses effectiveness over time due to volatilization and absorption
Solution Approach 1:
The patent changes the chemical composition parameters of the coating material from conventional oils and waxes to bitumen and its derivatives (including VTAE, flux, and other asphaltic materials). These materials have different physical and chemical properties including lower volatility and different absorption characteristics, which maintain coating effectiveness over extended storage periods while continuing to suppress dust formation.
Solution Approach 2:
The patent employs composite coating formulations that combine bitumen with other materials such as vegetable oils, waxes, and synthetic polymers. This composite approach creates a multi-layered coating system where each component contributes specific properties: bitumen provides long-term durability and binding, while supplementary materials enhance dust suppression and coating flexibility, resulting in a synergistic effect that maintains effectiveness over time.
2Shape
If waxes are applied below their melting point, then they coat the fertilizer surface, but they do not spread effectively; if applied above melting point, then they spread but are absorbed into particles
Solution Approach 1:
The patent changes the temperature parameter during coating application and the chemical composition of the coating material. Bitumen and its derivatives are applied at temperatures that maintain their viscosity for effective spreading without causing excessive absorption into fertilizer particles. The unique rheological properties of bitumen allow it to be applied in a temperature range that avoids the dilemmas faced by waxes.
Solution Approach 2:
The patent uses bitumen and related materials that can be applied as thinner, more uniform coatings compared to waxes. These materials form effective protective layers at lower application rates, reducing the total amount of coating material needed and minimizing absorption losses while still achieving complete surface coverage.
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 VTAE coating significantly reduces dust levels and caking tendencies in fertilizers, offering improved long-term storage and handling conditions without affecting the handling characteristics or agronomic properties, and demonstrates comparable or superior performance to bituminous coatings.
Implementation Method 1
both oil and waxes have limited binding properties, which are essential for long term fertilizer dust control and anti-caking abilities
Implementation Method 2
Over time, oil tends to volatilize and/or be absorbed into the fertilizer particles and lose their effectiveness
Data Source
AI summary
A method of reducing dust formation and/or caking in fertilizer or other particulates. The method comprises coating the fertilizer or other particulate in a coating comprising vacuum tower asphalt extender (VTAE). The VTAE may be a non-distilled fraction of vacuum distillation of used automotive and/or industrial oil. The VTAE may not be asphalt or bitumen, although the coating may further comprise bitumen.