Methods of manufacture for coated granular fertilizers

Abstract

A process of manufacturing a coated fertilizer comprising: providing at least partially coated fertilizer granules having an at least partial coating comprising a polymer and a wax; and conditioning the at least partially coated fertilizer granules at a temperature of 40 to 130° C. for a time of 1 minute to 4 hours, to form a coating comprising interpenetrating domains comprising polymer domains and wax domains.

Description

BACKGROUND

Granular fertilizers can be coated to reduce dust production and to slow the release of nutrients into the soil. To improve fertilizer uptake by the plant, the available fertilizer concentration in the soil should match the plant growth need. Due to various parameters such as soil erosion, volatilization of ammonia, and leaching of nitrates, only about 40% of currently available fertilizers like urea are absorbed by the plant and the remainder is lost to the environment. Hence, there remains a need in the art for improved coated fertilizer which allows for a higher utilization of the fertilizer by the plant.

SUMMARY

Described herein is a process of manufacturing a coated fertilizer comprising: providing at least partially coated fertilizer granules having an at least partial coating comprising a polymer and a wax; and conditioning the at least partially coated fertilizer granules at a temperature of 40 to 130° C. for a time of 1 minute to 4 hours, to form a coating comprising interpenetrating domains comprising polymer domains and wax domains.

The above described and other features are further set forth in the following figures, detailed description, and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The following is a brief description of the drawings wherein like elements are numbered alike and which are presented for the purposes of illustrating the exemplary embodiments disclosed herein and not for the purposes of limiting the same.

FIG. 1A is a scanning electron microscopic image of a sample at 500 times magnification with no pre-treatment.

FIG. 1B is a scanning electron microscopic image of the sample of FIG. 1A at 2000 times magnification with no pre-treatment.

FIG. 2A is a scanning electron microscopic image of a sample at 500 times magnification with 5 hours of pre-treatment.

FIG. 2B is a scanning electron microscopic image of the sample of FIG. 2A at 2000 times magnification with 5 hours of pre-treatment.

FIG. 3A is a scanning electron microscopic image of a sample at 500 times magnification with 10 hours of pre-treatment.

FIG. 3B is a scanning electron microscopic image of the sample of FIG. 3A at 2000 times magnification with 10 hours of pre-treatment.

FIG. 4A is a scanning electron microscopic image of a sample at 500 times magnification with 15 hours of pre-treatment.

FIG. 4B is a scanning electron microscopic image of the sample of FIG. 4A at 2000 times magnification with 15 hours of pre-treatment.

DETAILED DESCRIPTION

At least partially coated fertilizer granules having an at least partial coating comprising a polymer and a wax are conditioned at a temperature of 40 to 130° C. for a time of 1 minute to 4 hours, to form a coating comprising interpenetrating domains comprising polymer domains and wax domains. Within the aforementioned range the conditioning temperature can be 50 to 110° C., 60 to 100° C., or 60 to 80° C. Within the aforementioned time period the granules can be conditioned for a time of 2 to 4 hours.

The embodiments described herein relate to a coated fertilizer granule. The coating comprises interpenetrating domains of at least one polymer and at least one wax. The fertilizer granule is at least partially coated with a coating that comprises interpenetrating domains of at least one polymer and at least one wax.

It is desirable to improve the mechanical strength of the at least partially coated fertilizer granules. Mechanical strength can affect the ability of the fertilizer granules to withstand the normal handling procedures and can increase the effectiveness of the coating. It has surprisingly been discovered that pre-treating a surface of the fertilizer granule before applying the coating can improve the mechanical properties of the at least partially coated fertilizer granules as well as can improve the adherence of the coating to the fertilizer granule. The pre-treating, among other things, can include smoothing a surface of the fertilizer granule. Coated fertilizers containing a pre-treated fertilizer granule can have a significantly lower percent nitrogen release after 7 days as compared to coated fertilizers not containing a pre-treated fertilizer granule. For example, the pre-treated fertilizer granule can have a percent nitrogen release after 7 days of less than or equal to 70%, for example, less than or equal to 65%, for example, less than or equal to 60%. Pre-treatment can include smoothing of the fertilizer granule surface by pre-heating the granule to a temperature greater than or equal to 90° C. For example, the temperature can be greater than or equal to 100° C., for example, greater than or equal to 105° C., for example, greater than or equal to 125° C. The pre-treatment time can be greater than or equal to 5 hours, for example, greater than or equal to 10 hours, for example, greater than or equal to 15 hours, for example, greater than or equal to 20 hours.

After a coating has been applied (e.g. a 2% coating), the coated fertilizer containing the pre-treated fertilizer granule can be post-treated and weight loss measured. The 2% coating generally refers to a 2% polymer coating by weight. The coating can be applied by the processes described herein and gives a control sample allowing observation of the effect of the pre-treatment. Weight loss can be less for coated fertilizers containing the pre-treated fertilizer granule as compared to coated fertilizers not containing the pre-treated fertilizer granule. Post-treatment can include heating the pre-treated, at least partially coated granules at various temperatures and then measuring percent weight loss. Heating can include temperatures greater than or equal to 50° C., for example, greater than or equal to 60° C., for example, greater than or equal to 70° C., for example, greater than or equal to 80° C., for example, greater than or equal to 90° C., for example, greater than or equal to 100° C. The post-treatment heating time can be greater than or equal to 5 hours, for example, greater than or equal to 10 hours, for example, greater than or equal to 15 hours, for example, greater than or equal to 20 hours. The coated fertilizer containing the pre-treated fertilizer granule can have a percent weight loss of less than or equal to 0.20% after post-treatment, for example, less than or equal to 0.15%, for example, less than or equal to 0.10%.

The process disclosed herein can include pre-treating the fertilizer granule before the coating is applied. Pre-treating the fertilizer granule can assist in providing greater adherence of the coating to the fertilizer granule and in improving the ability of the coated fertilizer to withstand post formation tests as previously described herein. Pre-treating the fertilizer granule can include smoothing the surface of the fertilizer granule.

Smoothing the plurality of fertilizer granules can be achieved by heating, e.g., heating in a rotating drum or fluid bed. It is further contemplated that mechanical methods such as ball milling could also be used to smooth the plurality of fertilizer granules. In an exemplary method, a plurality of fertilizer granules are heated to a temperature greater than or equal to 90° C. for less than or equal to 15 hours. The temperature can be less than or equal to 110° C. For example, the temperature can be 90° C. to 100° C., or 100° C. to 110° C. The time can be 1 hour to 5 hours, or 5 hours to 15 hours. The fertilizer granules can be heated in an oven, a forced air oven, disc dryer, paddle dryer, rotary dryer, conveyor dryer, fluid bed dryer, or a combination comprising at least one of the foregoing. Optionally, the fertilizer granules can be cooled before coating.

In some embodiments, the at least partial coating on the fertilizer granules can be formed by at least partially dissolving a first polymer and a first wax in a first solvent to form a first solution; at least partially dissolving a second polymer and a second wax in a second solvent to form a second solution, wherein the concentration of wax in the first solution is different from the concentration of wax in the second solution, and contacting the first solution and the second solution with a plurality of fertilizer granules. The first solvent and second solvent can be evaporated from the fertilizer granules at a temperature less than the conditioning temperature. The first solution, the second solution, or both can further comprise an additional polymer.

The first polymer and second polymer can be the same or different. The first wax and the second wax can be the same or different. The first solvent and the second solvent can be the same or different.

In some embodiments, the at least partial coating on the fertilizer granules can be formed by at least partially dissolving a first polymer and a first wax in a first solvent to form a first solution; at least partially dissolving a second polymer and a second wax in a second solvent to form a second solution, wherein the first polymer is different from the second polymer, the first solvent is different from the second solvent, or the first wax is different from the second wax; and contacting the first solution and the second solution with a plurality of fertilizer granules. The first solvent and second solvent can be evaporated from the fertilizer granules at a temperature less than the conditioning temperature. The first solution, the second solution, or both can further comprise an additional polymer.

The fertilizer granules can be pre-treated before the first solution and the second solution are contacted with the fertilizer granule. Pre-treating the fertilizer granule can assist in providing greater adherence of the first solution and/or the second solution to the fertilizer granule and in improving the ability of the coated fertilizer to withstand post formation tests as previously described herein. Pre-treating the fertilizer granule can include smoothing the surface of the fertilizer granule.

As used herein the term “at least partially dissolving” is inclusive of suspending a material in a solvent. It is also inclusive of forming an emulsion.

The coated fertilizer comprising a fertilizer granule and a coating comprising interpenetrating domains of polymer domains and wax domains has a release rate which more closely matches plant growth rate and as a result has a higher utilization rate than coated fertilizer without the interpenetrating domains. Interpenetrating domains, as used herein, describe domains of different materials which penetrate each other mutually creating a morphology demonstrating distinct domains of separate materials which border one or more domains of a different material. These domains may be irregular in shape. A useful visual analogy is puzzle pieces in which adjoining pieces are domains formed from different materials. Without being bound by theory it is believed that when the polymer is applied it forms a non-continuous coating of polymer domains on the granules and at least some of the gaps in the polymer domains are filled with wax domains when the wax is applied.

The fertilizer granules can comprise nitrogen, phosphorus, or potassium sources such as ammonium nitrate, ammonium sulfate, ammonium sulfate nitrate, calcium nitrate, calcium ammonium nitrate, urea, urea-formaldehyde, monoammonium phosphate (“MAP”), diammonium phosphate, polyphosphate compounds, phosphate rock, single superphosphate (“SSP”), triple super phosphate, potassium nitrate, potassium chloride, potassium sulfate (“SOP” or potash), or a combination comprising at least one of the foregoing. In some embodiments, the fertilizer granules comprise urea. The amounts of nitrogen, phosphorus, or potassium sources included in the final fertilizer granules depends on the intended end use, and can be 0 to 60 wt. % for each component, based on the total weight of the fertilizer granule.

Additionally, magnesium sulfate and a source of one or more trace elements, i.e., micronutrients can be included, for example boron, calcium, chlorine, cobalt, copper, iron, manganese, molybdenum, nickel, sodium, zinc, or a combination comprising at least one of the foregoing can be present. These nutrients may be supplied in elemental form or in the form of salts, for example as sulfates, nitrates, or halides. The amount of plant micronutrients depends on the intended end use and can be, for example, 0.1 to 5 weight percent (wt. %), based on the total weight of the fertilizer granule.

Fillers can further be present in the granule, for example bentonite, calcite, calcium oxide, calcium sulfate (anhydrous or hemihydrate), dolomite, talc, sand, or a combination comprising at least one of the foregoing fillers.

Other components of granular fertilizers can include, for example, surfactants, nucleation agents, recycled fertilizer particles, nucleating soil conditioners such as calcium carbonate, activated carbon, elemental sulfur, biocides such as pesticides, herbicides, or fungicides, wicking agents, wetting agents, heat stabilizers, adhesives such as cellulose, polyvinyl alcohols, fats, oils, gum arabics, vinylidene ultraviolet stabilizers, antioxidants, reducing agents, colorants, binders (i.e., organochlorides, zeins, gelatins, chitosan, polyethylene oxide polymers, and acrylamide polymers and copolymers), and the like, as well as combinations comprising at least one of the foregoing.

The fertilizer granules can have any shape or size desired for their intended use. In some embodiments the fertilizer granules are substantially spherical. The fertilizer granules have an average particle diameter of 1.0 to 4.0 millimeters (mm). Within this range the average particle diameter can be greater than or equal to 1.5, or greater than or equal to 2.0 mm. Also within this range the average particle diameter can be less than or equal to 3.5, or less than or equal to 3.0 mm. In some embodiments at least 90% by weight of the fertilizer granules have a particle diameter of 2.0 to 4.0 mm Particle diameter is determined according to “Size Analysis—Sieve Method” IFDC S-107 issued by International Fertilizer Development Center (IFDC) which is the most common and internationally approved method used to determine fertilizer particle size.

The coating on the fertilizer granule comprises interpenetrating domains comprising polymer domains and wax domains. The polymer domains have a rate of biodegradation which differs from the rate of biodegradation of the wax domains when subjected to the same conditions. When the polymer domains comprise two or more polymers, each polymer has a different rate of biodegradation when subjected to the same conditions.

In some embodiments the polymer domains comprise a biopolymer. Exemplary polymers include polysaccharides, polyesters, lignin, and combinations comprising at least one of the foregoing. Exemplary polysaccharides include cellulose acetate, cellulose triacetate, starch acetate, or a combination comprising at least one of the foregoing. Exemplary polyesters include poly(butylene succinate), poly(butylene adipate terephthalate), poly(lactic acid), poly(lactic acid-co-glycolic acid), poly(butylene succinate), poly(caprolactone), poly(glycolide), poly(hydroxybutyrate), poly(hydroxybutyrate-co-hydroxy valerate), or a combination comprising at least one of the foregoing.

The cellulose acetate can have a weight average molecular weight (M_w) of 25,000 to 120,000 grams per mol (g/mol), for example, 35,000 to 70,000 g/mol.

The cellulose triacetate can have a M_w of 100,000 to 350,000 g/mol, for example, 125,000 to 300,000 g/mol, for example, 200,000 to 275,000 g/mol.

Starch acetate is a starch that has been acetylated to a degree of substitution (DS) of 1 to 3 with an acetyl value of 20% to 70%. As used herein, “acetyl value” refers to the weight percent (wt %) of acetic acid per unit measure of starch acetate. For example, an acetyl value of approximately 62.5 is equivalent to a DS of 3.0.

The poly(butylene succinate) (PBS) can have a M_w of 70,000 to 160,000 g/mol. In some embodiments the poly(butylene succinate) can have an M_w of 100,000 to 150,000 g/mol, for example, 120,000 to 140,000 g/mol. In some embodiments the poly(butylene succinate) can have a M_w of 75,000 to 125,000 g/mol, for example, 90,000 to 110,000 g/mol.

The poly(butylene adipate-terephthalate) (ECOFLEX™) can have a weight average molecular weight (M_w) of 30,000 to 120,000 g/mol, for example, 50,000 to 100,000 g/mol.

The poly(lactic acid) (PLA) can have a weight average molecular weight (M_w) of 30,000 to 250,000 g/mol. The PLA can comprise recycled PLA, scrap PLA or a combination comprising at least one of the foregoing. In some embodiments the poly(lactic acid) can have a M_w of 150,000 to 210,000 g/mol, for example, 175,000 to 190,000 g/mol. In some embodiments the poly(lactic acid) can have a M_w of 30,000 to 70,000 g/mol, for example, 40,000 to 65,000 g/mol.

The poly(lactic acid-co-glycolic acid) can have a M_w of 5,000 to 300,000 g/mol, for example, 10,000 to 250,000 g/mol, for example, 40,000 to 150,000 g/mol.

The poly(caprolactone) can have a M_w of 500 to 80,000 g/mol, for example, 5,000 to 70,000 g/mol, for example, 15,000 to 60,000 g/mol.

The poly(glycolide) can have a M_w of 500 to 60,000 g/mol, for example, 5,000 to 50,000 g/mol, for example, 20,000 to 40,000 g/mol.

The poly(hydroxybutyrate) can have a M_w of 10,000 to 500,000 g/mol, for example, 30,000 to 400,000 g/mol, for example, 75,000 to 350,000 g/mol.

The poly(hydroxybutyrate-co-hydroxy valerate) can have a M_w of 10,000 to 600,000 g/mol, for example, 30,000 to 500,000 g/mol, for example, 100,000 to 400,000 g/mol.

Lignin is a polymer of aromatic alcohols most commonly derived from wood. Lignin can be obtained by the Kraft process. Exemplary lignin includes Kraft lignin marketed under the name of INDULIN™ AT or PROTOBIND™ 1000.

In some embodiments, the polymer domains comprise at least two polymers. These polymers may be miscible so as to form a single domain together or may be immiscible and form separate polymer domains.

The coating comprises polymer domains in an amount of 50 to 80 wt %, based on the total weight of the coating.

The wax domains comprise a C₅-C₃₅ wax, polyethylene wax, mineral wax, biobased wax, shellac, or a combination comprising at least one of the foregoing. Waxes are liquid at 110 to 200° F. (43 to 95° C.). Exemplary waxes include natural petroleum waxes, including paraffin waxes (hard, crystalline, brittle waxes composed primarily of unbranched alkanes, typically having melting points of 48 to 70° C.), microcrystalline waxes (soft, amorphous, malleable waxes composed primarily of branched alkanes, typically having melting points of 54 to 95° C.), and fully refined paraffin waxes. Synthetic waxes can also be used, including polyethylene waxes having, for example, a degree of polymerization of 10 to 18 carbon atoms. Exemplary waxes that are commercially available include a petroleum wax, C30+ from Chevron Phillips Chemical (CP-Chem), 7089A, R-4408, and R-3053A available from International Group, Inc.

The coating comprises wax domains in an amount of 20 to 50 wt %, based on the total weight of the coating.

When coated on the fertilizer granules, the amount of the coating is less than or equal to 6 wt. %, for example, 0.1 to 6 wt. %, 0.5 to 5 wt. %, 2 to 5 wt. %, or 3 to 5 wt. %, based on the total weight of the coated fertilizer.

In any of the foregoing embodiments, the coatings can further comprise an adjuvant as known in the art, for example a colorant, an adhesion promoter, or a surfactant, provided that the adjuvant does not significantly adversely affect the desired properties of the coated fertilizer. For example, a surfactant can include a primary and secondary (C_16-30)alkylamine, a (C_16-30)fatty acid amide of a primary (C_16-30)alkylamine, or a (C_16-30)fatty acid ester of a (C_16-30)alkanol. Examples of the foregoing surfactants include cetyl amine, stearyl amine, arachidyl amine, behenyl amine, dicetyl amine, distearyl amine, diarachidyl amine, dibehenyl amine, di(hydrogenated tallow) amine, cetyl stearamide, stearyl stearamide, stearyl erucamide, erucyl erucamide.

Further, in any of the foregoing embodiments, the coating is disposed directly on the granule or other layers, that is, no intervening layers are present other than those described. The coating can be continuous or discontinuous. To optimize the sustained release features of the coated fertilizer, the coating covers 90 to 100% of the surface area of the fertilizer granule.

The thickness of the coating is adjusted to provide the desired sustained release and protection properties. In some embodiments, the total thickness of the coating is 20 to 70 micrometers. For example, the thickness can be greater than or equal to 25, or greater than or equal to 30 micrometers. For example, the thickness can be less than or equal to 65, or less than or equal to 60 micrometers.

Contacting the coating composition with a plurality of fertilizer granules can be achieved by spray coating (for example, top, bottom, or side spray coating), drum coating, pan coating, fluid bed coating, continuous pour coating, or any other method known to those of skill in the art. This coating can be done in a batch or in a continuous process. The granules can be coated with a single layer in a single coating application, or the granules can be coated with multiple layers of the same coating material, such as, 2, 3, 4, 5, or more layers. Evaporating and heating the at least partially coated fertilizer granules can occur in the same step or in sequential steps. Exemplary devices include a rotary evaporator, an oven, or the like.

Exemplary solvents include chloroform, toluene, methylene chloride, or a combination comprising one or more of the foregoing.

In some embodiments, the conditioning temperature is 70 to 100% of the melting temperature of the wax.

It is also contemplated that the coated fertilizer described herein may be mixed with uncoated fertilizer granules or with a coated fertilizer having a coating comprising a polymer but free of wax.

In use, the coated fertilizer is applied to the locus of a plant or seed, in particular the soil of a plant or seed to be fertilized.

The coated fertilizers having sustained release properties are further illustrated by the following non-limiting examples.

EXAMPLES

The materials used in Example 1 are described in Table 1.

	TABLE 1
	Component	Chemical Description	Source
	PBS	Poly(butylene succinate) 18127	Danimer
	PLA	Poly(lactic acid) 2003D	Natureworks
	C30+	Alpha-olefin wax	Chevron
			Phillips
	Methylene		Aldrich
	Chloride

General Procedures

Urea granulation. In urea granulation, seed particles, or recycled urea prills, are rotated through a central agglomeration tube via a high velocity air stream. A spray nozzle at the bottom of the agglomeration tube sprays urea melt onto the particles. Because the urea melt droplets are supplied at high velocities with air constantly passing through the granulator, the seeds are wetted and dried efficiently. As more urea melt is supplied by the spray nozzles, the urea particles grow in diameter and the process is concluded when the desired size has been achieved.

Preparation of coating formulations. Two coating solutions were made. The compositions of the coating solutions are shown in the tables below. Grams is abbreviated as “g” in the tables.

Coating procedure. The coating solutions were applied to the fertilizer granules using an air atomized spray in a rotating drum. The solvent was evaporated at 40-50° C. and the coated granules were then further conditioned using either a rotovap (20-30 revolutions per minute (rpm) for 20 minutes) or a drying oven under the conditions shown in the tables. The conditioned granules were tested for urea release.

Urea release test. The test is used to mimic a release profile of urea at 24 hours. 5 grams of coated granules were placed in 95 grams of deionized water at room temperature for the specified time period. The water was analyzed for nitrogen content at the end of the time period. Results are reported in percentage of total nitrogen and are shown in Tables 2 and 3. The urea release test gives information allowing for a calculation of how much urea is no longer bound by the coating. In Table 2, in Sample 1, 66.07% of the initial amount of coated urea used in the test has been released at the time of analysis without conditioning. Stated another way Sample 1 demonstrates that about 33.93% of the urea was still entrapped by the coating and gradually diffusing.

TABLE 2
Sample			No	Rotovap	Rotovap	Rotovap	Rotovap
#	Solution 1	Solution 2	conditioning	at 94° C.	at 99° C.	at 103° C.	at 110° C.
1	9 g PBS, 21 g	9 g PBS, 21 g	66.07%	15.86%	26.09%	69.77%	91.68%
	PLA, 15 g	PLA, 30 g
	C30+, 900 g	C30+, 900 g
	methylene	methylene
	chloride	chloride

TABLE 3
				70° C.	70° C.	70° C.	70° C.
Sample			No	for 1	for 2	for 3	for 4	70° C.
#	Solution 1	Solution 2	conditioning	hour	hours	hours	hours	overnight
2	9 g PBS, 21 g	9 g PBS A, 21 g	43.59%	17.97%	5.98%	7.97%	7.90%	58.03%
	PLA, 15 g	PLA, 30 g
	C30+, in 900 g	C30+, in 900 g
	methylene	methylene
	chloride	chloride
3	12 g PBS, 18 g	12 g PBS, 18 g	35.67%	23.79%	19.95%	19.92%	13.85%	—
	PLA, 15 g	PLA, 30 g
	C30+, in 900 g	C30+, in 900 g
	methylene	methylene
	chloride	chloride
4	15 g PBS, 15 g	15 g PBS, 15 g	29.81%	19.92%	11.91%	11.77%	19.81%	—
	PLA, 15 g	PLA, 30 g
	C30+, in 900 g	C30+, in 900 g
	methylene	methylene
	chloride	chloride

Table 2 shows that conditioning in a rotary evaporator at temperatures less than 103° C. slows the release of nitrogen from the urea granule. Conditioning at temperatures of 103° C. and higher actually increased the nitrogen release at 24 hours compared to the granules that were not conditioned.

Table 3 shows that conditioning in an oven at 70° C. for 2 to 4 hours slows the release of nitrogen from the urea granule compared to granules that weren't conditioned, conditioned for 1 hour and conditioned overnight.

Example 2

The materials used in Example 2 are described in Table 4.

TABLE 4
Component	Chemical Description	Source
PBS	Poly(butylene succinate) 1020MD	Showa Denko
PLA	Poly(lactic acid) 2003D	Natureworks
Chloroform		Aldrich
Toluene		Aldrich
Urea	Granular	SABIC

Formulations for the coatings are shown in Table 5.

	TABLE 5
	Solution 1	Solution 2
			Chloro-	Tolu-			Chloro-	Tolu-
Sample	PLA	PBS	form	ene	PLA	PBS	form	ene
#	(g)	(g)	(g)	(g)	(g)	(g)	(g)	(g)
9	21	9	630	270	9	21	630	270
10	21	9	630	270	9	21	630	270
11	21	9	450	450	9	21	450	450
12	21	9	450	450	9	21	450	450
13	21	9	0	900	9	21	0	900
14	21	9	450	450	9	21	450	450
15	21	9	450	450	9	21	450	450
16	21	9	450	450	9	21	450	450
17	21	9	450	450	9	21	450	450
18	21	9	450	450	9	21	450	450
19	21	9	450	450	9	21	450	450
20	21	9	450	450	9	21	450	450
21	21	9	450	450	9	21	450	450
22	21	9	450	450	9	21	450	450
23	21	9	450	450	9	21	450	450
24	21	9	450	450	9	21	450	450
25	21	9	450	450	9	21	450	450
26	21	9	450	450	9	21	450	450
27	21	9	450	450	9	21	450	450
28	21	9	450	450	9	21	450	450
29	21	9	450	450	9	21	450	450

The fertilizer granules were placed in a stainless steel pan, which was then placed in a forced-air convection oven set to a temperature of 90-110° C. for up to 15 hours. At different time intervals up to 15 hours, a small aliquot of approximately 5 grams of urea was collected and SEM images taken. FIGS. 1A-4B show the differences in the surface after pre-heating. After the urea was in the oven for a given time frame, the urea was then spray coated in a rotating drum with biopolymers that were dissolved in organic solvents. The solvent was evaporated, leaving behind the coating material on the surface of the fertilizer granule. Once the coating was deposited, the samples were again placed in a stainless steel pan and placed in a forced-air convection oven that is set to 70-90° C. for up to 15 hours to remove residual solvent that remains on the coated fertilizer granule. After a given time frame, approximately 5 grams of the coated fertilizer granule was placed in 95 grams of deionized water at room temperature (19-25° C.) and the percent nitrogen (% N) release was measured using a refractometer after 24 hours.

Additional samples from each batch were tested for abrasion resistance. The abrasion resistance tests consisted of placing a number of equally sized stainless steel balls and 100 ml of the coated fertilizer into a stainless steel drum having equally spaced flights. The drum was closed and then rotated at 30 revolutions per minute for 5 minutes. After 5 minutes, the stainless steel balls were separated from the coated fertilizer using a sieve at which point approximately 5 grams of the abraded coated urea was placed in 95 grams of deionized water at room temperature and the % N release was measured using a refractometer after 24 hours. Although described herein with respect to a force-air convection oven, other devices can be used, including, but not limited to, disc dryers, drum dryers, paddle dryers, rotary dryers, conveyor dryers, and/or fluid bed dryers.

Table 6 shows the % N release for before and after the abrasion test along with the pre- and post-heat treatment. Temperatures are listed in ° C. and time in hours.

	TABLE 6
	1-Day % N Release
	Pre-	Pre-	Post-	Post-	Before	After	Before
Sample	Heat	Heat	Heat	Heat	Abrasion	Abrasion	and After
#	T	Time	T	Time	Test	Test	Δ
9	None	0	70	15	21.06	55.49	34.43
10	None	0	70	15	28.04	51.13	23.09
11	None	0	70	15	16.12	40.23	24.11
12	None	0	70	15	11.31	25.31	14.00
13	None	0	70	15	29.47	67.62	38.15
17	None	0	70	15	19.39	65.93	46.54
18	None	0	70	15	22.94	62.35	39.41
19	105	15	70	15	12.85	20.21	7.36
20	105	15	70	15	16.04	20.12	4.08
21	105	15	70	15	6.11	8.09	1.98
22	105	15	70	15	29.88	27.11	−2.77
23	105	15	70	15	19.18	24.02	4.84
24	105	15	70	15	15.15	19.52	4.37
25	105	15	70	15	28.08	26.59	−1.49

As can be seen in FIGS. 1A-4B, the pre-treatment of a surface of the fertilizer granule provides a smoother surface of the fertilizer granule. FIGS. 1A, 2A, 3A, and 4 are at 500 times magnification, while FIGS. 1B, 2B, 3B, and 4B are at 2,000 times magnification. FIGS. 1A and 1B are the control sample with no pre-treatment. FIGS. 2A and 2B are a sample after pre-heating for 5 hours. FIGS. 3A and 3B are the sample in FIGS. 2A and 2B after pre-heating for 10 hours. FIGS. 4A and 4B are the sample in FIGS. 2A and 2B after pre-heating for 15 hours. As can be seen in the figures, a smoother surface is achieved with the longer heating. FIGS. 1A-4B further demonstrate that the surface morphology of the fertilizer granule undergoes transformation after it is heated in the forced-air convection oven. The sample in FIGS. 1A and 1B, which was not treated with heat, does not have a smooth surface compared to the samples that were heated for a period of time in FIGS. 2A-4B.

This transformation also appears to affect the % N release observed after the abrasion test after 34 hours as shown in Table 5. The % N release between the before abrasion and after abrasion test varies between 14.00% and 46.54% for samples that were not pre-heated. The % N release difference between samples that were pre-heated varies from no change to 7.36%.

The samples in Table 7 were also measured for % N release after 7 days and the percent weight loss after post-heat treatment.

	TABLE 7
	Pre-	Pre-	% N Release	Post-	Post-
Sample	Heat	Heat	1	7	Heat	Heat	% Wt.
#	T	Time	day	days	T	Time	Loss
14	None	0	21.36	81.62	70	15	0.40
15	None	0	18.90	77.00	70	15	0.37
16	None	0	19.78	79.09	70	15	0.24
26	105	15	25.87	69.00	70	15	0.06
27	105	15	18.58	69.29	70	15	0.10
28	105	15	13.55	65.18	70	15	0.10
29	105	15	17.86	56.26	70	15	0.06

As shown in Table 7, the samples that were pre-heated had a significantly lower % N release after 7 days as compared to the non-pre-heated samples. Furthermore, the post-heated (i.e., dried) samples which contained the pre-heated fertilizer granules after a 2% coating was applied had a significantly lower % weight loss as compared to the post-heated samples without the pre-heated fertilizer granule.

Embodiment 1: A process of manufacturing a coated fertilizer, comprising: providing at least partially coated fertilizer granules having an at least partial coating comprising a polymer and a wax; and conditioning the at least partially coated fertilizer granules at a temperature of 40 to 130° C. for a time of 1 minute to 4 hours, to form a coating comprising interpenetrating domains comprising polymer domains and wax domains.

Embodiment 2: The process of Embodiment 1, wherein providing at least partially coated fertilizer granules comprises: at least partially dissolving a first polymer and a first wax in a first solvent to form a first solution; at least partially dissolving a second polymer and a second wax in a second solvent to form a second solution, wherein the concentration of wax in the first solution is different from the concentration of wax in the second solution; and contacting the first solution and the second solution with a plurality of fertilizer granules.

Embodiment 3: The process of Embodiment 2, wherein the first wax and the second wax are the same, the first polymer and the second polymer are the same and the first solvent and second solvent are the same.

Embodiment 4: The process of Embodiment 1, wherein providing at least partially coated fertilizer granules comprises: at least partially dissolving a first polymer and a first wax in a first solvent to form a first solution; at least partially dissolving a second polymer and a second wax in a second solvent to form a second solution, wherein the first polymer is different from the second polymer, the first solvent is different from the second solvent, or the first wax is different from the second wax; and contacting the first solution and the second solution with a plurality of fertilizer granules.

Embodiment 5: The process of any one of Embodiments 2 to 4, further comprising evaporating the first solvent and second solvent from the fertilizer granules after contacting them with the first solution and second solution at a temperature less than the conditioning temperature.

Embodiment 6: The process of any one of Embodiments 2 to 5, wherein the first solution, the second solution, or both further comprise an additional polymer.

Embodiment 7: The process of any one of Embodiments 1 to 6, wherein the conditioning temperature is 70 to 100% of the melting temperature of the first wax, second wax or both.

Embodiment 8: The process of any one of Embodiments 1 to 7, further comprising using a rotating drum to contact the coating on the fertilizer granule.

Embodiment 9: The process of any one of Embodiments 1 to 8, wherein the fertilizer granules comprise urea.

Embodiment 10: The process of any one of Embodiments 1 to 9, wherein the polymer domains comprise a biopolymer.

Embodiment 11: The process of Embodiment 10, wherein the biopolymer is a polysaccharide, a polyester, lignin or a combination comprising at least one of the foregoing.

Embodiment 12: The process of any of one of Embodiments 1 to 11, wherein the wax domains comprise a C₅-C₃₅ wax.

Embodiment 13: The process of any one of Embodiments 2 to 12, wherein the first solution and the second solution comprise the same polymers.

Embodiment 14: The process of Embodiment 13, wherein the polymers are in the same concentration.

Embodiment 15: The process of any one of Embodiments 1 to 14, wherein the first wax and the second wax are the same wax.

Embodiment 16: The process of any one of Embodiments 2 to 15, wherein the first solvent and the second solvent are the same.

Embodiment 17: A coating process of any one of Embodiments 1 to 16, further comprising: pre-treating the fertilizer granule with conditions effective to improve surface adherence properties to the coating to obtain a pre-treated fertilizer granule; and at least partially coating the pre-treated fertilizer granule.

Embodiment 18: The process of Embodiment 17, comprising pre-treating the fertilizer granule by heating to a temperature greater than or equal to 90° C., for a time period of greater than or equal to 5 hours.

Embodiment 19: The process of Embodiment 18, wherein the pre-treated fertilizer granule comprises a smoothed surface.

Embodiment 20: The process of any one of Embodiments 17 to 19, wherein the pre-treated fertilizer granule has a percent nitrogen release after 7 days of less than or equal to 70%, preferably, less than or equal to 65%, more preferably, less than or equal to 60%.

The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. “Or” means “and/or.” The endpoints of all ranges directed to the same component or property are inclusive and independently combinable. The suffix “(s)” as used herein is intended to include both the singular and the plural of the term that it modifies, thereby including at least one of that term (e.g., “colorant(s)” includes at least one colorant). “Optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where the event occurs and instances where it does not. Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this invention belongs. Substantially as described herein generally refers to greater than or equal to 75%, for example, greater than or equal to 75%, for example, greater than or equal to 95%.

As used herein, a “combination” is inclusive of blends, mixtures, alloys, reaction products, and the like. Compounds are described using standard nomenclature. For example, any position not substituted by any indicated group is understood to have its valency filled by a bond as indicated, or a hydrogen atom. A dash (“-”) that is not between two letters or symbols is used to indicate a point of attachment for a substituent. For example, —CHO is attached through carbon of the carbonyl group.

All references cited herein are incorporated by reference in their entirety. While typical embodiments have been set forth for the purpose of illustration, the foregoing descriptions should not be deemed to be a limitation on the scope herein. Accordingly, various modifications, adaptations, and alternatives can occur to one skilled in the art without departing from the spirit and scope herein.

Claims

1. A process of manufacturing a coated fertilizer comprising: pre-treating a fertilizer granule with conditions effective to improve surface adherence properties to a coating by heating the fertilizer granule to a temperature greater than or equal to 90° C. for a time period of greater than or equal to 1 hour, to obtain a pre-treated fertilizer granule;at least partially coating the pre-treated fertilizer granule to obtain an at least partially coated fertilizer granule, wherein the coating comprises a polymer and a wax; andconditioning the at least partially coated fertilizer granule at a temperature of 40 to 130° C. for a time of 1 minute to 4 hours, to form a conditioned coating comprising interpenetrating domains comprising polymer domains and wax domains.

2. The process of claim 1, wherein at least partially coating the pre-treated fertilizer granule comprises: at least partially dissolving a first polymer and a first wax in a first solvent to form a first solution;at least partially dissolving a second polymer and a second wax in a second solvent to form a second solution, wherein the concentration of wax in the first solution is different from the concentration of wax in the second solution; andcontacting the first solution and the second solution with a plurality of fertilizer granules.

3. The process of claim 2, wherein the first wax and the second wax are the same, the first polymer and the second polymer are the same and the first solvent and second solvent are the same.

4. The process of claim 1, wherein at least partially coating the pre-treated fertilizer granule comprises: at least partially dissolving a first polymer and a first wax in a first solvent to form a first solution;at least partially dissolving a second polymer and a second wax in a second solvent to form a second solution, wherein the first polymer is different from the second polymer, the first solvent is different from the second solvent, or the first wax is different from the second wax; andcontacting the first solution and the second solution with a plurality of fertilizer granules.

5. The process of claim 2, further comprising evaporating the first solvent and second solvent from the fertilizer granules after contacting them with the first solution and second solution at a temperature less than the conditioning temperature.

6. The process of claim 2, wherein the first solution, the second solution, or both further comprise an additional polymer.

7. The process of claim 1, wherein the conditioning temperature is 70 to 100% of the melting temperature of the first wax, second wax or both.

8. The process of claim 1, further comprising using a rotating drum to contact the coating on the fertilizer granule.

9. The process of claim 1, wherein the fertilizer granules comprise urea.

10. The process of claim 1, wherein the polymer domains comprise a biopolymer.

11. The process of claim 10, wherein the biopolymer is a polysaccharide, a polyester, lignin or a combination comprising at least one of the foregoing.

12. The process of claim 1, wherein the wax domains comprise a C5-C35 wax.

13. The process of claim 2, wherein the first solution and the second solution comprise the same polymers.

14. The process of claim 13, wherein the polymers are in the same concentration.

15. The process of claim 1, wherein the first wax and the second wax are the same wax.

16. The process of claim 1, wherein the first solvent and the second solvent are the same.

17. The process of claim 1, comprising pre-treating for a time period of greater than or equal to 5 hours.

18. The process of claim 1, wherein the pre-treated fertilizer granule comprises a smoothed surface.

19. The process of claim 1, wherein the pre-treated fertilizer granule has a percent nitrogen release after 7 days of less than or equal to 70%.