High Value Organic-Enhanced Inorganic Fertilizers

Abstract

The invention is directed to manufacture of fertilizer having commercial levels of nitrogen supplemented with organic substances. The process treats organic matter with acid causing hydrolysis of organic polymers after which the mix is injected with nitrogen. The resultant sterilized and liquefied organic matter is disbursed over recycled material for the production of granules. Because the process allows for the controlled addition of acids and ammonia, desired levels of components can be achieved. The process is scalable, odor controlled and safe thereby allowing for the location of biosolid processing facilities in most any location. Further, the fertilizer of the invention provides a dual nitrogen-release profile when applied to crops. After application to soil, fertilizer of the invention releases an immediate bolus of nitrogen, similar to traditional ammonium sulfate, followed by continued slow release of nitrogen typically over a season.

1 . A system for the manufacture of a fertilizer comprising:
 a mixer configured to blend organic material with an odor control agent forming blended organic material;   a first reaction or pressure vessel containing one or more inlets configured for the blended organic material and an acid, wherein the blended organic material is mixed with the acid and heated to a first predetermined temperature and pressurized to a first predetermined pressure for a period of time forming a liquid;   a second reaction or pressure vessel containing one or more inlets configured for the liquid and an ammonia source, wherein the liquid is mixed with ammonia from the ammonia source and heated to a second predetermined temperature and pressurized to a second predetermined pressure for a second period of time; and   a granulator wherein the ammoniated liquid is mixed with preformed granules and heated to form dried granules of the fertilizer.   
     
     
         2 . The system of  claim 1 , wherein the ammonia source is liquefied or gaseous ammonia under pressure. 
     
     
         3 . The system of  claim 1 , wherein the first and second reaction or pressure vessels each contain an agitator. 
     
     
         4 . The system of  claim 1 , further comprising a screening process to size fertilizer granules, and one or more cooling and coating apparatus to reduce temperature and control dust prior to storage. 
     
     
         5 . The system of  claim 1 , further comprising:
 a conveyer for transporting the organic material to the mixer and another conveyer for transporting the blended organic material to the first reaction or pressure vessel;   a pressurized piping system that transports acidified organic material from the first reaction or pressure vessel to the second reaction or pressure vessel, ammonia into the second reaction or pressure vessel; and disperses the ammoniated liquid to the granulator.   
     
     
         6 . The system of  claim 1 , further comprising one or more screens for selecting granules of a predetermined size and a rotary cooler for cooling and polishing the sized granules. 
     
     
         7 . The system of  claim 1 , further comprising a dust control apparatus that collects and recycles dust from the granulator. 
     
     
         8 . The system of  claim 1 , further comprising a water recovery system whereby water extracted from the organic material during processing is recovered and recycled. 
     
     
         9 . The system of  claim 1 , wherein the first reaction or pressure vessel is a pipe-cross reactor, the second reaction or pressure vessel is a pipe-cross reactor, or both the first and second reaction or pressure vessels are each pipe-cross reactors. 
     
     
         10 . The system of  claim 1 , wherein the first reaction or pressure vessel is a reaction vessel and the second first reaction or pressure vessel is a pressure vessel. 
     
     
         11 . The system of  claim 1 , wherein the first and second reaction or pressure vessels are the same vessel. 
     
     
         12 . A system for the manufacture of a fertilizer comprising:
 a mixer that blends organic material;   one or more first reaction or pressure vessels containing one or more inlets configured for the blended organic material and an acid, wherein the blended organic material is mixed with the acid provided through the one or more inlets that liquefies the organic material generating both heat and pressure within the vessel;   one or more second reaction or pressure vessels containing one or more inlets configured for input of the liquid organic material from the one or more first reaction or pressure vessels and an ammonia inlet from an ammonia source that is added to the one or more second reaction or pressure vessels after the organic material has been liquefied; and   a granulator wherein the ammoniated liquid is mixed with preformed granules and heated to form dried granules of the fertilizer.   
     
     
         13 . The system of  claim 12 , wherein the preformed granules are recycled fertilizer granules. 
     
     
         14 . The system of  claim 12 , wherein the ammonia source is liquefied or gaseous ammonia under pressure. 
     
     
         15 . The system of  claim 12 , wherein the one or more first and/or second reaction or pressure vessels contain an agitator. 
     
     
         16 . The system of  claim 12 , further comprising a screening process to size fertilizer granules, and one or more cooling and/or coating apparatus to reduce temperature and control dust prior to storage. 
     
     
         17 . The system of  claim 12 , further comprising:
 a conveyer for transporting the organic material to the mixer and another conveyer for transporting the blended organic material to the one or more first reaction or pressure vessels;   a pressurized piping system that transports the acid to the one or more first reaction or pressure vessel and/or ammonia to the one or more second reaction or pressure vessels; and disperses the ammoniated liquid to the granulator.   
     
     
         18 . The system of  claim 12 , further comprising one or more screens for selecting granules of a predetermined size and a rotary cooler for cooling and polishing the sized granules. 
     
     
         19 . The system of  claim 12 , further comprising a dust control apparatus that collects and recycles dust from the granulator. 
     
     
         20 . The system of  claim 12 , further comprising a water recovery system whereby water extracted from the organic material during processing is recovered and recycled.