WO2017156610A1

WO2017156610A1 - Method for producing organic or organic-mineral fertilizers in granule form, and fertilizers obtained by this method

Info

Publication number: WO2017156610A1
Application number: PCT/BR2017/050055
Authority: WO
Inventors: Osney STEFANUTO; Humberto AMARAL
Original assignee: Stefanuto Osney; Amaral Humberto
Priority date: 2016-03-16
Filing date: 2017-03-14
Publication date: 2017-09-21

Abstract

The present invention relates to a method for producing organic-mineral fertilizers for agriculture, having a spherical or circular shape, from residues from organic compounds in various kinds of industries, which are first subjected to a separation step in which particles having a diameter of 3 mm or less are separated and conveyed to a mixer, where an agglomerating agent can be added, besides other additives desired, forming a homogeneous mixture with 10 to 40% humidity which is passed through a low-pressure extruder and transformed into pellets which are conveyed while still green to a rotary spheroidiser that operates at a peripheral speed of 5 to 20 m/s, causing an increase in the density of the granules and transforming the pellets into spheres, which may also be surface-coated, and finally dried until their humidity ranges from 5 to 25%, finally producing granules that exhibit a grain rupture charge measured according to the protocol indicated in example 1 ranging from 0.50 to 2.50 kgf, and exhibiting a density gain in relation to the organic compounds of 5 to 40%.

Description

PROCESS FOR MANUFACTURING FERTI LI ZANTES ORGAN COS OR ORGAN- Ml NERAI S IN GRANULAR FORM AND FERTI LI ZANTES OBTAINED BY SUCH PROCESS Field of Application

[001] The present invention relates to a process for manufacturing organic or organo-mineral fertilizers with improved mechanical strength, density and segregation properties employable in agriculture.

State of the art

[002] Processes for obtaining small spherical or non-spherical granulates or pellets from organic based fertilizers with various types of additives are already known to the person skilled in the art. JPH091 1,066, JPH09268093, EP1 174404, JP2001097795, KR20070029428, JP 0706262-1 and BR0706262-1 teach the process of obtaining spherical granulates based on various types of organic materials and industrial waste.

[003] The problem with commercially available organic-based granules is that they do not have adequate mechanical rheological properties, which causes problems in their application in the field. They generate a lot of dust, have problems of flow and segregation within the fertilizer application machine in the crop. The present invention aims to eliminate these problems.

Objectives of the invention

[004] The present invention has as objectives:

- develop a process for manufacturing fertilizers in spherical or circular granular form and that said fertilizers have improved mechanical properties, density and composition;

- Develop a sustainable process employing organic waste from various types of industries, thus representing a general economy and benefit to the environment;

- Develop a process that presents good performance, reduced costs and does not generate effluents or waste to the environment;

- solve a problem of the man of the art with the application of fertilizers of size or shape other than the size-specific circulars according to the invention, which generate a lot of dust or flow problems in fertilizer application machines in agriculture, or even generate segregation in mechanized application when mixed with chemical fertilizer. -Develop a productive process of organic fertilizers with optimized physical characteristics (for example: low dust generation, controlled particle size distribution and humidity, adequate mechanical resistance, etc.) and as a vehicle for carrying various compounds needed for the vegetative cycle of the main crops. from the market. In such a way that during its production process it can be added with various chemical compounds. (eg micro and macro nutrients, hormones, etc.), and / or inoculated with various living microorganisms beneficial to such cultures (eg Bradyrhizobium, Azospirillum, etc.).

Brief Description of the Invention

[005] A spherical or circular fertilizer manufacturing process has been developed starting from waste organic compounds from various types of industries that are initially subjected to a particle separation step of less than or equal to 3 mm in diameter. directed to a mixer where they may receive addition of binder in addition to other desired additives, forming a homogeneous moisture mixture of between 10 and 40% which is sent to a low pressure extruder and transformed into pellets, which, while still green, are directed. for a rotating spheroidizer operating at a peripheral speed of 5 to 20 m / s, which increases the density of the pellets, which turns the pellets into spheres, which can still be surface coated and finally dried to moisture. reach the range between 5 and 25%, resulting in the end of the granules that present the breaking load of the grain measured according to protocol indicated in example 1 ranging from 0.50 to 2.50 kgf and having a density gain over organic compounds of 5 to 40%.

Description of the Figures

[006] The invention will be better understood in the light of the accompanying figures, given by way of example only but not limitation, in which:

Fig. 1 illustrates the flowchart of the process of manufacturing fertilizer in granular form according to the invention;

Fig. 2: illustrates the equipment employing for hardness testing of fertilizer granules according to the invention.

Detailed Description of the Invention

[007] A process for manufacturing fertilizers in spherical granular form was developed from the various available organic compounds, mainly crop residues, animal manure, miscellaneous composting, peat, lignite, leonardite, uncontaminated wastes from industrial processes such as such as residues from fermentation processes, residues from the sugar cane industry, the paper and timber industry, filter cake from the sugar cane industry, poultry waste, etc. May or may not suffer from the addition of macro and micro nutrients, hormones, amino acids, bacteria, fungi and / or any molecules whose presence is desired from a nutritional or functional point of view (fighting situations that may damage a particular culture).

The inventive activity of the process lies in the production of granules of sufficient mechanical strength and density to undergo the entire life cycle of a fertilizer (production, storage, transportation, customer storage, mixing with other fertilizers for mechanized application, application of pure fertilizer), without the formation of fines and disintegration of granules, which would impair their performance in the field, whether segregation occurs during application when mixed with other compounds such as granulated urea, various granulated sulfates and nitrates, potassium, etc., either because the use of mechanization in the distribution of fertilizer in the soil requires mechanical strength of the granules to withstand the stresses of the process without their fragmentation, thus providing a controlled release of the nutrients contained in the granule. Nevertheless, when maintaining the integrity of the granule, there is a favorable habitat for the development of microorganisms within such granule, facilitating their gradual transfer to the soil and protecting them from natural factors (eg radiation). until they settle on the ground.

The process begins from the moment organic matter is sent to a separator, typically a vibrating or rotating screen, but can be any separation device, where larger particles are separated, typically fragments above 3 mm, generating two streams of material, where the coats are directed to a mill, typically a hammer or pin mill, but can be any grinding or deagglomerating device, after which they return to the separation step again. It is a stream of material already selected and suitable for the mixing / additive process, where at this stage the material is mixed with the other components of the desired final formulation, as well as the binding agent chosen from the group comprising: water, sugar, dextrose, various syrups. , acrylates, vinyl compounds, fermentation by-products, etc., or mixtures thereof. This step happens in a Plow mixer, and may occur in other types, such as ribbons, nautamixers, paddle mixes, etc.

[01 0] The product then proceeds to the low pressure extrusion step, where the product is extruded to Pellet shape and its density is partially increased, this preferably occurs in a basket-type extruder. At the end of this process the material is in the form of cylinders of diameter preferably about 3.25 to 6 mm and length ranging from about 3 to 10 mm, also called a pellet. The good performance of this process step is closely linked to the moisture content of the organic matter and should be controlled in values between 10 and 40%, depending on the extrusion characteristics of each material employed.

[01 1] After extruding the pellet of the still green material, it is directed to a rotating spheroidizer, which consists of a flat surface circular steel rotor provided with slots and arranged in the horizontal plane, operating at peripheral speeds in the range of 5 to 20 m / s where the material increases its density due to compaction efforts arising from the combination of centripetal force and friction of the disc grooves. At the same time, the pellet becomes spherical, not necessarily circular, due to the rolling effort that arises from the combination of the moving disc and the static wall of the spheriodizer. This step can be done continuously or in batches depending on the organic substrate employed and the type of equipment employed.

[01 2] At this stage of the process, the surface of the grain can be coated with different components, such as a surface hardener to further improve mechanical strength and shorten the process time.

[01 3] After extrusion the material is sent to a dryer where it loses moisture up to the range of 5 to 25% and acquires specified hardness. Since this dryer can be rotary drum type, tunnel type, greenhouse type, fluidized bed type, drying chamber type, etc. In this step it is important to control the residual moisture, because the water bridges will guarantee, with or without a binder, the mechanical resistance of the grain. Excess water, in addition to impairing grain resistance, can cause the emergence of undesirable fungi and bacteria in the final product.

[014] After this step the product is ready to be packed or stacked (silage) for bulk delivery.

[01 5] Organic or organo-mineral fertilizers may comprise up to 100% by weight in their organic matter composition.

[01 6] Granular-form organic or organo-mineral fertilizers according to the invention have a composition which may contain:

- solid organic components: for example organic carbon; and / or liquid organic components: such as humic and fulvic acids, plant extracts (eg seaweed extract), cane molasses;

- various mineral components;

- macro and micro nutrients;

- hardeners;

- Water;

- special additives depending on the application.

[01 7] Organic component may be chosen from the group comprising: barnyard or manure manure, poultry waste, slaughterhouse waste: bones, dried blood or blood meal (extracted from bones and fat in pressure tanks), horns and hulls, oilseed residues: by-products of the oil industry, vinasse, by-products of the mills after alcohol distillation, filter bag residue: by-product of the sugar mill, slurry, fishmeal, bone meal, peat, oil shale, leonardite castor bean pie humus worm, bark, bagasse and other solid residues from various commercial crops (eg soya, maize, sunflower, hortifruti), charcoal waste, miscellaneous fermentation process residues (eg from the beverage industry), starch industry residues , etc.

[01 8] Mineral components can be nitrogen, phosphate, potassium, calcareous, and sulfur and its variations.

[01 9] Nitrogen components include: Chilean saltpeter or potassium nitrate, potassium saltpeter or sodium nitrate and potassium nitrate, ammonium sulphate, ammonium nitrate, calcium nitrate, synthetic sodium nitrate, urea.

Phosphate components may be selected from the group comprising: mineral phosphates found in deposits known as apatites, phosphorites, cuprolite, depending on nature, Olinda phosphorite or natural phosphate of organic origin, ground bones, guanos, simple superphosphate or monocalcium phosphates , double or triple superphosphate, precipitated or dicalcium phosphate phosphates, derived from tricalcium phosphates by treatment with hydrochloric acid and added lime milk, Thomas slag or iron industry by-product, serranophosphate, superphosphate, oxidized phosphate, ammonium phosphate and thermophosphate.

Potassium components may also be employed as for example: silvine, carnalite, potassium chloride, potassium sulfate, potassium magnesium sulfate, potassium nitrate, or even limestone components.

[022] As micronutrients that can be employed we can mention:

-Boro, in the form of: ulexite, sodium octaborate, boric acid, among others;

-Zinc, in the forms of oxide and salt, among others;

-Copper, in the forms of oxide and salt, among others;

-Manganese, in the forms of oxide and salt, among others;

-Cobalt, in the forms of oxide and salt, among others;

- Molybdenum, in the forms of oxide and salt, among others;

Iron, in the forms of oxide and salt, among others.

[023] The composition according to the invention still has binding or hardening agents, among others water, polyacrylates, polyvinyls, gums, alcohols, etc.

[024] The composition may still contain microorganisms such as fungi, bacteria, protozoa and actinomycetes, among which we can cite genera:

-Bradyrizhobium SP;

Bacillus Subtilis and Licheniformis;

-Lactobacillus Plantarum;

-Trichoderma longibrachiatum;

-Trichoderma SP; Bacillus SP;

Azospirillum SP.

[025] Organic or organo-mineral fertilizers may comprise up to 100% by weight in their organic matter composition.

According to one embodiment of the invention, the granular fertilizer has:

40 to 80% organic substrate;

5 to 30% macro-nutrients;

1 to 10% micronutrients;

0 to 3% polymeric hardener;

5 to 15% water.

According to another embodiment of the invention, the granular fertilizer has:

40 to 60% organic substrate;

0 to 30% macro-nutrients;

0 to 10% of micronutrients;

20-50% sulfur;

0 to 3% polymeric hardener;

5 to 15% water.

According to a still further embodiment of the invention, the granular fertilizer has: 70 to 90% organic substrate;

0 to 20% seaweed extract;

0 to 10% of micronutrients;

0 to 3% polymeric hardener;

5 to 15% water.

According to another embodiment of the invention, the granular fertilizer has:

40 to 60% organic substrate;

1 to 5% zinc oxide;

1 to 5% copper oxide;

1 to 10% charcoal;

5 to 10% cane molasses;

1 to 6% phosphorite;

0 to 3% polymeric hardener;

5 to 15% water.

All of the above formulations may contain the aforementioned microorganisms.

Granulated fertilizers according to the invention have a spherical or circular shape with a diameter less than or equal to 10 mm, breaking strength of the grain measured according to protocol indicated in example 1 ranging from 0.5 to 2.50 kgf and a density gain with respect to organic compounds of 5 to 40%.

[032] The attached Figure 1 illustrates the process flowchart.

The examples below are for illustrative purposes only and should not be taken for purposes of limitation thereof.

-Example 1:

[034] Test of mechanical strength of the granules:

[035] The mechanical strength of the granules obtained by the process in question was evaluated using a simple compression equipment, illustrated in the attached Figure 2, developed exclusively for this purpose. This equipment was designed to record the breaking load that the bead supports (in kgf), applied by means of a spindle (2) which has at its end an oscillating compression plate (3), ensuring the application of force in the normal direction. to the horizontal plane. This spindle is displaced axially by operating the handle (1) clockwise, when the compression plate meets the bead that is positioned on a load cell (4), a compression load on it is developed, and as the spindle is displaced an increase in this force occurs up to a maximum value corresponding to the breaking load of the bead. After the rupture event this force decreases due to its breakdown. This maximum load value is recorded by a specific indicator (6).

[036] In this test the mechanical strength of the granules of various fertilizers commonly used in mechanized haul fertilization in different types of soils found in the national territory and in different crops was evaluated. As well as the strength of the granule obtained by the process in question, formulated with the following composition:

48% peat with carbon content around 12%;

25% sulfur mesh 80;

9.4% boric acid;

8% zinc sulfate;

9.3% water;

0.3% polyacrylate hardener.

[037] The results found for grain disruption load (average of 10 trials per product) and their tested products are shown in table 1 below:

Compound Bursting Load

(average of 10 trials)

Triple Phosphate 1, 88 kgf Super Simple 2.02 kgf

Urea 2.16 kgf

Organo-Mineral 1, 35 kgf

TABLE 1

[038] Comparative tests of apparent density increase:

[039] Bulk density is a very relevant parameter in the commercial viability of such a project as it directly impacts the transportation cost of the finished product and its storage cost.

[040] Tests were performed to evaluate the apparent density gain presented by three organic raw materials which are potential candidates for processing: poultry residue, peat and sugarcane industry filter cake.

[041] The methodology used is described below:

APPARENTLY DENSITY

^■ Weigh an empty 500 mL graduated beaker into a precision balance (g).

^■ Carefully insert 500 mL of sample into the beaker.

^■ Weigh the filled beaker and note (g).

^■ Tap the beaker 30 times against a 1 inch high rubber surface at 2-second intervals between strokes.

^■ Measure volume (mL) after beats (apparent volume).

^■ Subtracting the value obtained from weighing the filled beaker from the value obtained by the weighing value from the empty beaker, the result will correspond to the mass of the sample (g).

^■ For density determination, divide sample mass in grams by volume

apparent in mL according to the formula described below:

Dap = Mass (a)

Apparent volume (mL)

DETERMI NATION OF VOLTAGE UMI S BY CAPSULE

^■ Place the capsule on the balance and note the weight.

^■ Add the product to the capsule and note the weight of the capsule with the product.

^■ Place in oven according to the temperature of the product to be analyzed and allow to dry to constant mass.

^■ Remove the product from the oven and cool to room temperature and weigh the dish with the dry product.

^■ Calculate the result of humidity according to the formula below:

Humidity (% m / m) = (b-a) = d

(bc) = e (e / d ^* 100) =% m / m.

Where:

a = empty capsule mass;

b = mass of capsule with wet product;

c = mass of capsule with product after drying.

[042] Following this methodology, for the mentioned raw materials were found the results indicated in Table 2 below:

Example 2:

[043] Field Tests:

[044] Field tests were performed in the molds of mechanized fertilization used in modern agriculture to evaluate variables, considered relevant in the applicability of the product obtained by the process in question:

1) Distribution uniformity test (coverage).

2) Test of mechanical damage suffered by the bead.

Segregation test when applied in admixture with another non-organic fertilizer.

[045] The tests were conducted using a Ford Brand Model 5030 tractor. Coupled to a Vicon Brand TDS 1 150 double disc rotary distributor. The set speed was 5 km / h at a speed of 1,500 RPM, which corresponds to an application volume of approximately 275 kg / ha, considering a coverage range of 12 meters.

[046] The set traveled over a flat and straight area over a distance of 50 meters, 2 samples were collected on each side of the distributor, the first being at 5 meters from the set displacement axis and the second at 10 meters. of it, totaling 4 samples for each pass. Three passes were made, totaling 12 samples. Since the values found in the first pass were used as reference for calibration of the distributed equipment, and in the case of a situation present at the beginning of each application in the field, these data were also analyzed.

[047] The sample composition of the fertilizer tested obtained by the process in question was:

48% peat with carbon content around 12%;

25% sulfur mesh 80 9.4% boric acid;

8% zinc sulfate;

9.3% water;

0.3% polyacrylate hardener.

[048] Distribution Uniformity (Coverage) Test

[049] The results of the granular distribution (coverage) uniformity test are shown in Table 3 below:

TABLE 3

[050] From these results we can conclude that even in a machine tuning situation we have a Coefficient of Variation in the order of 9% ( ^1s collection), and in running this deviation decreases and stabilizes in values below 2% (2 ^s and 3 ^S collections), values considered quite satisfactory (Dallmeyer 1986).

[051] Mechanical Damage Test

[052] The samples collected were then analyzed in a dry sieving test using a 1.5mm aperture sieve, and the granules retained in this sieve were considered "intact".

[053] Weight percentages of whole granules found were:

TABLE 4

[054] Segregation test when applied in admixture with other non-organic fertilizer:

[055] Segregation test on the application of a mixture of 50% organo-mineral fertilizer and 50% granulated urea:

[056] The tests were conducted with the same equipment and under the same conditions as the previous test, thus generating four samples. In these samples, the proportion by weight of each component constituting the applied mixture was analyzed. arriving at the results shown in Tables 5 and 6 below:

TABLE 6

Claims

1 . Process for Manufacturing Organic or Organo-Mineral Fertilizers in Granular Form characterized by obtaining spherical or circular fertilizer granules from waste from organic compounds of various types of industries that are initially subjected to a particle separation step of smaller or smaller diameter. 3 mm, which are directed to a mixer where they may receive addition of binder in addition to other desired additives, forming a homogeneous moisture mixture of 10 to 40% which is sent to a low pressure extruder and pelleted, which, while still green, are directed to a rotating spheroidizer operating at a peripheral speed of 5 to 20 m / s, which transforms the pellets into spheres, which increases the density of granules that may still be surface coated. finally dried until the humidity reaches the range between 5 and 25%, giving rise to the final granules having a breakthrough load measured according to the protocol indicated in example 1 ranging from 0.5 to 2.50 kgf and having a density gain over organic compounds of 5 to 40%.

Process for Manufacturing Organic or Organo-Mineral Granular Form Fertilizers according to Claim 1, characterized in that it employs various available organic compounds, mainly crop residues, animal waste, miscellaneous composting, peat, lignite, leonardite, uncontaminated waste from industrial processes. , such as residues from fermentation processes, industry residues: from sugarcane, the paper and timber industry, filter cake from the sugarcane industry, poultry waste, etc.

Process for Manufacturing Granular Form Organic or Organo-Mineral Fertilizers according to Claim 1, characterized in that the organic base may undergo the addition of macro and micro nutrients, hormones, amino acids, bacteria, fungi and / or any molecules whose presence is desired. nutritional or functional point of view (combating situations that may harm a particular culture).

Process for Manufacturing Granular Form Organic or Organo-Mineral Fertilizers according to Claim 1, characterized in that the organic-based particles larger than 3 mm are separated, milled and returned to the initial separation stage.

Process for Manufacturing Granular Form Organic or Organo-Mineral Fertilizers according to Claim 1, characterized in that it employs as binding agent: water, sugar, dextrose, various syrups, acrylates, vinyl compounds, fermentation by-products, etc.

Process for Manufacturing Granular Form Organic or Organo-Mineral Fertilizers according to Claim 1, characterized in that the extrusion occurs at low pressure.

Process for Manufacturing Granular Form Organic or Organo-Mineral Fertilizers according to Claim 1, characterized in that in the extrusion step, the moisture content of the pellet is partially increased.

Process for Manufacturing Granular Form Organic or Organo-Mineral Fertilizers according to Claim 1, characterized in that at the end of the extrusion process the pellets have a diameter between about 3.25 to 6 mm and a length ranging between about 3 and 10 mm.

Process for Manufacturing Granular Form Organic or Organo-Mineral Fertilizers according to Claim 1, characterized in that the spheroidization of the pellets may occur in batch or continuous.

Process for Manufacturing Granular Form Organic or Organo-Mineral Fertilizers according to Claim 1, characterized in that the surface of the granules may be coated with different components, such as a surface hardener to improve their mechanical strength and shorten time. of the process.

1 1. Granular Form Organic or Organo-Mineral Fertilizers according to claims 1 to 10, characterized in that they have a spherical or circular shape, having a diameter less than or equal to 10 mm, breaking strength of the grain measured according to the protocol indicated in example 1 ranging from 0.5 to 2.50 kgf and having a density gain over organic compounds of 5 to 40%.

Granular Form Organic or Organo-Mineral Fertilizers according to Claim 11, characterized in that it has a composition comprising:

- solid organic components and / or liquid organic components;

- various mineral components;

- macro and micro nutrients;

- hardeners;

- Water;

- special additives depending on the application.

Granular Form Organic or Organo-Mineral Fertilizers according to Claim 12, characterized in that it comprises an organic component which may be selected from the group comprising: barnyard or manure manure, poultry waste, slaughterhouse waste: bones, dried blood or flour of blood (extracted from bones and fat in pressure tanks), horns and hooves, oil residues: by-products of industry oil, vinasse, by-products of alcohol distillation plants, bagasse filter residue: sugar mill by-product, slurry, fishmeal, bone meal, peat, oil shale, leonardite, castor cake, worm humus , husks, bagasse and other solid residues from various commercial crops (eg soya, maize, sunflower, hortifruti), charcoal residues, miscellaneous fermentation process residues (eg from the beverage industry), starch industry residues, etc. .

Granular Form Organic or Organo-Mineral Fertilizers according to claim 12, characterized in that they comprise mineral components which may be nitrogenous, phosphate, potassic, calcareous, as well as sulfur and its variations.

Granular Form Organic or Organo-Mineral Fertilizers according to Claim 12, characterized in that they comprise micronutrients such as: Boron, in the form of: ulexite, sodium octaborate, boric acid, among others; Zinc, Copper, Manganese, Cobalt, Molybdenum, Iron, in the forms of oxide and salt, among others.

Organic or Organo-Mineral Granular Form Fertilizers according to Claim 12, characterized in that they comprise binding or hardening agents, among others water, polyacrylates, polyvinyls, gums, alcohols, etc.

Granular Form Organic or Organo-Mineral Fertilizers according to Claim 12, characterized in that they comprise microorganisms such as fungi, bacteria, protozoa and actinomycetes, or selected from the group consisting of: Bradyrizhobium sp; Bacillus subtilis and Licheniformis; Lactobacillus plantarum; Trichoderma longibrachiatum; Trichoderma sp; Bacillus sp; Azospirillum sp.

Granular Form Organic or Organo-Mineral Fertilizers according to Claim 12, characterized in that they comprise up to 100% by weight in their organic matter composition.

Granular or Organic or Organic Mineral Fertilizers according to Claim 12, characterized in that they comprise:

40 to 80% organic substrate;

5 to 30% macro-nutrients;

1 to 10% micronutrients;

0 to 3% polymeric hardener;

5 to 15% water.

Organic or Organo-Mineral Fertilizers in Granular Form according to claim 12, comprising:

40 to 60% organic substrate;

0 to 30% macro-nutrients; 0 to 10% of micronutrients;

20-50% sulfur;

0 to 3% polymeric hardener;

5 to 15% water.

21 Granular Form Organic or Organo-Mineral Fertilizers according to Claim 12, characterized in that they comprise:

70 to 90% organic substrate;

0 to 20% seaweed extract;

0 to 10% of micronutrients;

0 to 3% polymeric hardener;

5 to 15% water.

Granular Form Organic or Organo-Mineral Fertilizers according to Claim 12, characterized in that they comprise:

40 to 60% organic substrate;

1 to 5% zinc oxide;

1 to 5% copper oxide;

1 to 10% charcoal;

5 to 10% cane molasses;

1 to 6% phosphorite;

0 to 3% polymeric hardener;

5 to 15% water.