U.S. patent application number 13/821986 was filed with the patent office on 2013-12-19 for agricultural binder system, agricultural blend, and process of forming an agricultural blend.
This patent application is currently assigned to HARSCO CORPORATION. The applicant listed for this patent is Stephen R. Miranda, Kimberly A. Papania. Invention is credited to Stephen R. Miranda, Kimberly A. Papania.
Application Number | 20130333428 13/821986 |
Document ID | / |
Family ID | 49754677 |
Filed Date | 2013-12-19 |
United States Patent
Application |
20130333428 |
Kind Code |
A1 |
Miranda; Stephen R. ; et
al. |
December 19, 2013 |
AGRICULTURAL BINDER SYSTEM, AGRICULTURAL BLEND, AND PROCESS OF
FORMING AN AGRICULTURAL BLEND
Abstract
The present disclosure describes an agricultural blend and a
process of forming an agricultural blend. The agricultural blend
includes a slag by-product from a process having a slag other than
stainless steel slag or includes 11 atomic % silicon from a soluble
compound and total silicon of less than about 30 atomic % silicon
or greater than about 39 atomic % silicon. The process includes
producing a slag by-product and blending the slag by-product with a
liquid binder system to form the agricultural blend, the slag not
being stainless steel slag.
Inventors: |
Miranda; Stephen R.;
(Coraopolis, PA) ; Papania; Kimberly A.; (Sarver,
PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Miranda; Stephen R.
Papania; Kimberly A. |
Coraopolis
Sarver |
PA
PA |
US
US |
|
|
Assignee: |
HARSCO CORPORATION
Camp Hill
PA
|
Family ID: |
49754677 |
Appl. No.: |
13/821986 |
Filed: |
September 9, 2011 |
PCT Filed: |
September 9, 2011 |
PCT NO: |
PCT/US11/51086 |
371 Date: |
June 24, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12879432 |
Sep 10, 2010 |
|
|
|
13821986 |
|
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|
|
Current U.S.
Class: |
71/23 ; 106/481;
106/501.1; 71/25; 71/27 |
Current CPC
Class: |
B09B 3/0041 20130101;
C08L 5/00 20130101; B09B 3/0025 20130101; C05D 3/00 20130101; B09B
3/0033 20130101; C05B 5/00 20130101; C09J 189/00 20130101; C05G
3/44 20200201; C08K 5/098 20130101; C08L 89/00 20130101; C08L 91/00
20130101; C05D 3/02 20130101; C05D 3/04 20130101; C05D 3/02
20130101; C05D 3/04 20130101; C05B 5/00 20130101; C05D 3/00
20130101; C09J 103/02 20130101 |
Class at
Publication: |
71/23 ; 71/27;
71/25; 106/501.1; 106/481 |
International
Class: |
C05G 3/00 20060101
C05G003/00 |
Claims
1. An agricultural blend, comprising: a slag by-product, the slag
by-product including a soluble compound having silicon; and a
binder system; wherein the slag by-product in the agricultural
blend is from a process having a slag other than stainless steel
slag.
2. The agricultural blend of claim 1, wherein the slag other than
stainless steel slag is selected from the group consisting of
carbon steel slag, aluminum slag, phosphate slag, copper slag, zinc
slag, non-ferrous slag, argon oxygen decarburization slag, alloy
steel slag, blast furnace slag, blast oxygen furnace slag, coal
slag, or combinations thereof.
3. The agricultural blend of claim 1, wherein the agricultural
blend is agglomerated.
4. The agricultural blend of claim 1, wherein the agricultural
blend is pelletized.
5. The agricultural blend of claim 1, further comprising a sulfate
source.
6. The agricultural blend of claim 1, further comprising a
micronutrient packet.
7. The agricultural blend of claim 1, wherein the soluble compound
includes monosilic acid.
8. The agricultural blend of claim 1, wherein the soluble compound
includes polysilic acid.
9. The agricultural blend of claim 1, wherein the soluble compound
includes an organosilicon.
10. The agricultural blend of claim 1, wherein the soluble compound
includes calcium silicate.
11. The agricultural blend of claim 1, wherein the soluble compound
includes calcium inosilicate.
12. An agricultural blend, comprising: a soluble compound; an
insoluble compound; and a binder system; wherein the agricultural
blend includes greater than 10 atomic % silicon from the soluble
compound; and wherein the agricultural blend includes total silicon
of less than about 30 atomic % silicon or greater than about 39
atomic % silicon.
13. The agricultural blend of claim 12, wherein the soluble
compound and the insoluble compound are a by-product from a
non-metal slag.
14. The agricultural blend of claim 12, wherein the soluble
compound and the insoluble compound are a by-product from a metal
slag.
15. The agricultural blend of claim 12, further comprising a
sulfate source.
16. The agricultural blend of claim 12, wherein the soluble
compound includes monosilic acid.
17. The agricultural blend of claim 12, wherein the soluble
compound includes polysilic acid.
18. The agricultural blend of claim 12, wherein the soluble
compound includes calcium silicate.
19. The agricultural blend of claim 12, wherein the soluble
compound includes calcium inosilicate.
20. A process of forming an agricultural blend, the process
comprising: producing a slag; producing a slag by-product from the
slag, the slag by-product including a soluble compound having
silicon; and blending the slag by-product with a liquid binder
system to form the agricultural blend; wherein the slag is not
stainless steel slag.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a national stage application for PCT
Patent Application PCT/US2011/051063, titled "AGRICULTURAL BLEND
AND PROCESS OF FORMING AN AGRICULTURAL BLEND," filed Sep. 9, 2011,
which is a continuation-in-part of U.S. patent application Ser. No.
12/879,432, titled "AGRICULTURAL BLEND AND PROCESS OF FORMING AN
AGRICULTURAL BLEND," filed Sep. 10, 2010, both of which are hereby
incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention is directed to agricultural blends and
processes of forming agricultural blends. More specifically, the
present invention is directed to agricultural blends containing
silicon.
BACKGROUND OF THE INVENTION
[0003] Specific minerals are known to stimulate plant growth in
agriculture. For example, fertilizers and other additives can
contain silicon compounds, such as, calcium silicate, magnesium
silicate, potassium silicate, and sodium silicate. Fertilizers and
the other additives can deliver these minerals, these compounds, or
combinations of these minerals and these compounds to a plant or to
soil. The method of delivering the minerals or compounds, the
crystal structure of the minerals or compounds, and the combination
of the minerals or compounds impacts the efficacy of the
fertilizers and other additives, for example, by impacting the
solubility of them. Soluble compounds are able to travel through
soil, plants, and/or portions of plants (such as a cell wall)
better than insoluble compounds.
[0004] The minerals or compounds in the fertilizers or other
additives are produced in several forms. For example, the minerals
or compounds in the fertilizers or other additives can be natural
(for example, mined) or synthetic (for example, a by-product of an
industrial process). Utilizing synthetic minerals or compounds,
such as, by-products, can be environmentally beneficial by reducing
waste and economically beneficial by creating economic value to
existing waste.
[0005] One such by-product is slag. Slag is generally perceived as
a waste material. However, most slag can be used in road surfaces,
roofing, or cementitious products. The source of slag impacts the
composition of the slag and, thus, the end-use of the slag or
portions of the slag. For example, blast furnace slag is known to
be used in roads and cementitious products; however, it has
previously been perceived as undesirable for agricultural products
due to its composition. Stainless steel slag (greater than 10.5
weight % Chromium is indicative of a stainless steel product) has
been used for roads and cementitious products as well as
agricultural products due to its compositions. However, stainless
steel slag can be limited in availability.
[0006] Additionally or alternatively, making of agricultural blends
from slag sources, especially pelletized agricultural blends, can
involve difficulty in dispersion during blending, pellet strength,
and combinations thereof.
[0007] Applying such agricultural blends can also be difficult.
Silicon from different sources, such as different composition
slags, can have a different structure. In addition, silicon can
have different structures based upon process parameters, such as,
the cooling rate of the slag, and/or based upon physical
characteristics, such as granular size of the compound. These
different structures can affect solubility of compounds containing
silicon. Solubility impacts the ability for silicon to be processed
by plants and/or the ability to sequester heavy metals. Thus,
information about silicon that fails to identify whether the
silicon is in a soluble compound can be misleading or unreliable by
failing to properly identify the impact of including such silicon.
In addition, lacking such information prevents proper
identification of preferred minimum ranges of silicon from soluble
compounds.
[0008] What is needed is an agricultural blend and process of
forming an agricultural blend using slag from sources other than
stainless steel and/or including soluble compounds.
BRIEF DESCRIPTION OF THE INVENTION
[0009] In an exemplary embodiment, an agricultural blend includes a
slag by-product, the slag by-product including a soluble compound
having silicon and a binder system. The slag by-product in the
agricultural blend is from a process having a slag other than
stainless steel slag.
[0010] In another exemplary embodiment, an agricultural blend
includes a soluble compound, an insoluble compound, and a binder
system. The agricultural blend includes greater than 10 atomic %
silicon from the soluble compound. The agricultural blend includes
total silicon of less than about 30 atomic % silicon or greater
than about 39 atomic % silicon.
[0011] In another exemplary embodiment, a process of forming an
agricultural blend includes producing a slag, producing a slag
by-product from the slag, the slag by-product including a soluble
compound having silicon, and blending the slag by-product with a
liquid binder system to form the agricultural blend. The slag is
not stainless steel slag.
[0012] Other features and advantages of the present invention will
be apparent from the following more detailed description of the
preferred embodiment, taken in conjunction with the accompanying
drawings which illustrate, by way of example, the principles of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a flow diagram of an exemplary industrial process
according to the disclosure.
[0014] Wherever possible, the same reference numbers will be used
throughout the drawings to represent the same parts.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Provided is an agricultural blend and a process of forming
an agricultural blend. The agricultural blend can be, can be a
portion of, can be a pre-cursor to, or can include a fertilizer, a
mineral soil amendment (for example, calcium and magnesium
silicate), a soil conditioner (for water and stress management, the
enhancement of plant vitality, the improvement of soil water and
air movement, nutrient holding capacity, or combinations thereof),
a liming agent (for example, calcium and magnesium silicate), an
additive to improve soil pH, an additive to decrease metal toxicity
issues, or any suitable combination thereof.
[0016] Embodiments of the present disclosure include being
environmentally-friendly by utilizing waste or by-product streams
from one or more industrial processes, having the ability for
calcium silicate and/or magnesium silicate to be retained in
agricultural substances for longer periods of time, being capable
of increasing soil pH, being capable of decreasing metal toxicity
(for example, from Al, Mn, or heavy metals), improving cation
exchange capacity, improving crop tolerance (for example, to
drought, frost, disease, and/or insects by increasing strength of
cell wall and/or by further protecting from disease/pathogen
attack), improving plant productivity (for example, by increasing
the rate and/or amount of photosynthesis through increased
production of chlorophyll and/or carbohydrates), decreasing lodging
(for example, by increasing structural integrity with increased
silicon in roots, shoots, and/or leaves), reducing or eliminating
till utilization (for example, by increasing lateral and vertical
movement), improving handling (for example, by 25%), improving flow
ability (for example, by 15%), improving storability (for example,
by 30%), providing increased soluble silicon (for example, greater
than about 10 lbs/ton) and combinations thereof.
[0017] As shown in FIG. 1, according to an exemplary process 100,
in one embodiment, slag 104 produced from an industrial process or
from a blast furnace that is a slag-producing process 106 is used
in forming an agricultural blend 102, for example, a powder, a
granule, and/or an agglomerated solid. The slag-producing process
106 is one unitary process or a combination of processes linked,
for example, by transportation of materials. After the
slag-producing process 106 forms the slag 104, the slag 104 is
processed through any suitable separation process 108 to form one
or more slag by-products 110, including the agricultural blend 102.
In one embodiment, the one or more slag by-products 110 are a
combined flow from more than one source and/or the composition of
the one or more slag by-products 110 is adjusted by increasing or
decreasing a concentration of one or more of the sources. In one
embodiment, the one or more slag by-products 110 are from the slag
104 of various geographic or geologic regions and/or are from
sources produced at different periods of time.
[0018] In embodiments with the slag-producing process 106 having
multiple slag by-products 110, one of the slag by-products 110 is a
silicon-containing by-product 111 that is used for the agricultural
blend 102; another slag by-product 110 is a separated-slag
by-product 112 that is used for a different purpose, such as road
material, roofing, cementitious material, engineered fill, acid
mine drainage (AMD) remediation, sludge stabilization, and
combinations thereof.
[0019] The agricultural blend 102 formed by the silicon-containing
by-product 111 includes silicon in one or more compounds. The
silicon within the agricultural blend 102 is in a soluble compound
or a combination of the soluble compound and an insoluble compound.
The total silicon in the agricultural blend 102 includes all
soluble silicon and insoluble silicon. In some embodiments, the
total silicon of the agricultural blend 102 is less than about 30
atomic % or greater than about 39 atomic %. In some embodiments,
less than about 25 atomic %, less than about 15 atomic %, between
about 5 atomic % and about 25 atomic %, between about 15 atomic %
and about 25 atomic %, between about 20 atomic % and about 25
atomic %, between about 1 atomic % and about 5 atomic %, or any
suitable combination or sub-combination thereof. Alternatively, in
other embodiments, the total silicon of the agricultural blend 102
is between about 40 atomic % and about 53 atomic %, between about
45 atomic % and about 50 atomic %, between about 50 atomic % and
about 53 atomic %, greater than about 45 atomic %, greater than
about 50 atomic %, or any suitable combination or sub-combination
thereof.
[0020] Additionally or alternatively, in some embodiments, the
silicon from the soluble compound within the agricultural blend 102
is at or above a predetermined amount. For example, in one
embodiment, the silicon from the soluble compound in the
agricultural blend is between about 10 atomic % and about 20 atomic
%, between about 10 atomic % and about 15 atomic %, between about
15 atomic % and about 20 atomic %, between about 12 atomic % and
about 15 atomic %, between about 10 atomic % and about 12 atomic %,
greater than 10 atomic %, greater than 12 atomic %, greater than 15
atomic %, greater than 20 atomic %, or any suitable combination or
sub-combination thereof.
[0021] The soluble compound in the agricultural blend 102 is any
suitable composition containing silicon and capable of being in
solution. For example, in some embodiments, the soluble compound
includes a monosilic acid, a polysilic acid, an organosilicon,
calcium silicate, calcium inosilicate, or other suitable forms of
silicon capable of being in solution. In one embodiment, the
soluble compound is any suitable compound having a solubility that
is greater than or equal to the least soluble form of calcium
silicate. In one embodiment, the soluble compound is any suitable
compound capable of travelling through a cell wall of a plant or
otherwise available to the plant due to its ability to dissolve. In
contrast, in some embodiments, the insoluble compound is silic acid
(quartz in solution), amorphous silica, magnesium silicate, coarse
or crystalline silicates, or other similar forms of silicon
generally incapable of being in solution. In one embodiment, the
insoluble compound is any suitable compound having a solubility
that is less than or equal to the most soluble form of magnesium
silicate. In one embodiment, the insoluble compound is any suitable
compound incapable of travelling through a cell wall of a plant or
is otherwise unavailable to the plant due to its inability to
dissolve.
[0022] The application of the agricultural blend 102 treats soil to
form treated soil. In this embodiment, the agricultural blend 102
increases the rate of plant growth in the treated soil. The
agricultural blend 102 is applied to the soil by any suitable
technique to form the treated soil and is absorbed by the plant
(for example, in one embodiment, at a concentration substantially
equal to that of the concentration of the silicon from the soluble
compound in the treated soil). In one embodiment, the agricultural
blend 102 is applied through a spreader. In one embodiment, the
agricultural blend 102 is applied by banding, for example, by
depositing the agricultural blend 102 along with a seed into a
furrow in the soil prior to the furrow being closed. In this
embodiment, plant growth is unexpectedly at a rate that is even
faster than plant growth based upon spreading the agricultural
blend 102 without banding.
[0023] In one embodiment, the amount of silicon and/or the amount
of the soluble compound are determined, for example, in the treated
soil formed from the application of the agricultural blend 102 to
soil. As used herein, the term "soil" refers to any medium capable
of sustaining plant growth or capable of being modified to sustain
plant growth. For example, soil includes, but is not limited to,
dirt, detritus, clay, rock, gravel, cement, mud, peat, sand,
soil-less mixes, other suitable media, or combinations thereof. The
determination is of total silicon, silicon from the soluble
compound, and/or silicon from the insoluble compound.
[0024] In determining silicon from the soluble compound, in one
embodiment, an extractor is used for quantifying the amount of the
silicon in the soluble compound. In one embodiment, the extractor
for extracting the silicon and determining the amount of silicon
from the soluble compound is or includes
Na.sub.2CO.sub.3+NH.sub.4NO.sub.3. In one embodiment, the
extracting is performed by drying a sample of the agricultural
blend 102 then weighing a predetermined amount of the sample of the
agricultural blend 102, for example, about 0.1000 g, then adding
the extractor to the sample at a predetermined amount, for example,
50 ml of Na.sub.2CO.sub.3 to 10 g/L and/or 50 ml of
NH.sub.4NO.sub.3 to 16 g/L, prior to agitating/mixing at a
predetermined rate, for example, 60 rpm for 1 hour, to form the
extracting solution. In this embodiment, the extracting takes up to
about five days and then is colorimetrically analyzed, for example,
by complexing the silicon with ammonia molybdate and complexing
phosphorus with ascorbic acid.
[0025] In one embodiment, the determination of the amount of the
silicon from the soluble compound takes less than about five days.
In a further embodiment, the duration is less than about 1 day,
less than about 12 hours, less than about 10 hours, less than about
8 hours, less than about 6 hours, less than about 5 hours, less
than about 4 hours, about 1 day, about 12 hours, about 10 hours,
about 8 hours, about 6 hours, about 5 hours, about 4 hours, or any
suitable combination or sub-combination thereof.
[0026] In one embodiment, a bath, such as a water bath, is prepared
at a predetermined temperature, for example, within the range of
between about 70.degree. C. and about 100.degree. C., between about
80.degree. C. and about 100.degree. C., between about 90.degree. C.
and about 100.degree. C., between about 70.degree. C. and about
90.degree. C., between about 80.degree. C. and about 90.degree. C.,
at about 70.degree. C., at about 75.degree. C., at about 80.degree.
C., at about 85.degree. C., at about 90.degree. C., at about
95.degree. C., at about 100.degree. C., or any suitable combination
or sub-combination thereof. In one embodiment, the predetermined
temperature is selected for highest extraction and lowest loss of
the extractor through evaporation.
[0027] In one embodiment, the extracting solution including the
agricultural blend 102 and the extractor is positioned within the
bath for a predetermined duration, for example, at least 30
minutes, at least 1 hour, at least 2 hours, at least 3 hours, at
least 4 hours, at least 6 hours, at least 8 hours, about 30
minutes, about 1 hour, about 2 hours, about 3 hours, about 4 hours,
about 6 hours, about 8 hours, or any suitable combination or
sub-combination thereof. In one embodiment, the predetermined
duration is selected for suitability for extraction and/or to avoid
diminishing solubility. In one embodiment, a predetermined volume
of distilled water is added to the extracting solution to reduce or
eliminate silicon precipitation. For example, in one embodiment,
about 18 mL of the distilled water is added to about 100 mL of the
extracting solution.
[0028] In one embodiment, the extracting solution is removed from
the bath and allowed to sit for a predetermined waiting time, for
example, at least 1 hour, at least 2 hours, at least 3 hours, at
least 6 hours, at least 12 hours, at least 15 hours, at least 16
hours, about 1 hour, about 2 hours, about 3 hours, about 6 hours,
about 12 hours, about 15 hours, about 16 hours. In one embodiment,
the predetermined waiting time is the shortest time permitting the
sample to completely cool.
[0029] In one embodiment, the determination shows that applying the
agricultural blend 102 to the soil increases silicon from the
soluble compound in the soil, silicon from the soluble compound in
one or more of the plants within the soil, or combinations thereof.
In one embodiment, the amount of silicon from the soluble compound
in the treated soil is between about 4% and 19% of the total
silicon and/or the concentration of the silicon from the soluble
compound is at least a predetermined amount, for example, greater
than about 15 parts per million, greater than about 20 parts per
million, greater than about 30 parts per million, greater than
about 40 parts per million, greater than about 50 parts per
million, greater than about 60 parts per million, greater than
about 70 parts per million, greater than about 80 parts per
million, greater than about 90 parts per million, greater than
about 100 parts per million, an increase of about 15 parts per
million, an increase of about 20 parts per million, an increase of
about 30 parts per million, an increase of about 40 parts per
million, an increase of about 50 parts per million, an increase of
about 60 parts per million, an increase of about 70 parts per
million, an increase of about 80 parts per million, an increase of
about 90 parts per million, an increase of about 100 parts per
million, or any suitable combination or sub-combination thereof. In
one embodiment, the amount of an increase in the silicon from the
soluble compound corresponds to the type of plant growing, for
example, an increase of greater than about 20 parts per million for
rice or sugarcane or an increase of greater than about 90 parts per
million for wheat.
[0030] In one embodiment, the agricultural blend 102 provides
silicon to soil, a plant, or a portion of a plant (such as through
a cell wall or into a cell wall) that is measurable, for example,
through a regulatory body. In one embodiment, the agricultural
blend 102 provides silicon that is measurable by an analytical
technique approved by the American Association of Plant Food
Controlled Officials and/or the Association of Official Analytical
Chemists.
[0031] In one embodiment, the applying of the agricultural blend
102 to the soil sequesters one or more heavy metals, such as
non-toxic metals (for example, iron, cobalt, nickel, copper,
manganese, molybdenum, and zinc), toxic metals (for example,
mercury, plutonium, barium, and lead), selectively toxic metals
(for example, vanadium, tungsten, arsenic, chromium, and cadmium),
any other metal having a specific gravity above about 5, or any
suitable combination or sub-combination thereof. The heavy metals
are sequestered by forming a substantially inert particle including
the agricultural blend 102 and the heavy metals. For example, the
agricultural blend 102 interacts with and treats the soil such that
the heavy metals form inert particles, thereby sequestering the
heavy metals.
[0032] In one embodiment, the agricultural blend 102 is applied
under predetermined conditions for increased effect. For example,
in one embodiment, the agricultural blend 102 is applied under
acidic soil conditions. In one embodiment, the agricultural blend
102 is applied during a period of increased growth during the
life-cycle of the plants in the soil, for example, the spring or
the fall, a one-month period, two-month period, or three-month
period with higher amounts of moisture and/or sunlight than other
periods of similar durations. In one embodiment, the agricultural
blend 102 is applied under alkaline soil conditions, for example,
when the agricultural blend 102 includes sulfates. In one
embodiment, the agricultural blend 102 is applied during a period,
such as, a pre-growth period, a post-dormancy period, a dormancy
period, a post-harvest period, a fallow period, any other suitable
period, or combinations thereof.
[0033] The content and/or source of the slag 104 producing the
agricultural blend 102 as the slag by-product 110 impacts the
compositions of the agricultural blend 102. In one embodiment, the
slag-producing process 106 forms a product 114, such as carbon
steel, aluminum, phosphate, copper, zinc, non-ferrous material,
alloy steel, iron, combustion products and energy (such as from
coal), any product that has less than 10 weight % chromium (greater
than 10.5 weight % being indicative of a stainless steel product),
or any other suitable product. In further embodiments, the product
114 of the slag-producing process 106 has less than about 8%,
chromium, less than about 6% chromium, less than about 4% chromium,
between about 2% and about 8% chromium, between about 2% and about
6% chromium, between about 4% and about 8% chromium, between about
4% and about 6% chromium, or any suitable combination or
sub-combination thereof.
[0034] In one embodiment, the slag 104 from the slag-producing
process 106 is a metal slag, such as, carbon steel slag, aluminum
slag, copper slag, zinc slag, non-ferrous slag, argon oxygen
decarburization slag (AOD slag), alloy steel slag, stainless steel
slag (for heavy metal sequestration or combined by-products), blast
furnace slag (for example, from the production of iron), blast
oxygen furnace slag (BOFS), or combinations thereof. In one
embodiment, the slag 104 from the slag-producing process 106 is a
non-metal slag, such as, phosphate slag or coal slag.
[0035] In one embodiment, the slag 104 from the slag-producing
process 106 is copper slag and/or has a general composition
including, by weight, between about 30% and about 40% SiO.sub.2,
between about 5% and about 10% CaO, between about 1% and about 5%
MnO, between about 2% and about 4% Al.sub.2O.sub.3, between about
2% and about 3% Zn, a balance of Fe, and incidental impurities.
[0036] In one embodiment, the slag 104 from the slag-producing
process 106 is zinc slag and/or has a general composition
including, by weight, about 20% FeO, about 15% CaO, about 20%
SiO.sub.2, about 5% Al.sub.2O.sub.3, about 10% PbO, a balance ZnO,
and incidental impurities.
[0037] In one embodiment, the slag 104 from the slag-producing
process 106 is non-ferrous slag and/or has a general composition
including, by weight, about 15% CaO, about 15% SiO.sub.2, about
5.4% Al.sub.2O.sub.3, about 1.3% MgO, about 1.1% K.sub.2O, about
0.9% Na.sub.2O, about 4.8% Zn, about 2.0% Pb, a balance FeO, and
incidental impurities. In a further embodiment, the slag 104
includes, by weight, about 15% CaO, about 15% SiO.sub.2, about 5.4%
Al.sub.2O.sub.3, about 1.3% MgO, about 1.1% K.sub.2O, about 0.9%
Na.sub.2O, about 4.8% Zn, about 2.0% Pb, about 0.7% C, about 0.6%
Cu, about 0.4% SO.sub.4.sup.2-, about 0.4% MnO, about 0.2%
TiO.sub.2, about 0.2% PO.sub.4.sup.3-, trace components (such as,
about 0.1% B, about 0.04% SrO, and about 0.04% Cl.sup.-) a balance
FeO, and incidental impurities.
[0038] In one embodiment, the slag 104 from the slag-producing
process 106 is blast furnace slag and/or has a general composition
including, by weight, between about 32% and about 45% CaO, between
about 5% and about 15% MgO, between about 32% and about 42%
SiO.sub.2, between about 7% and about 16% Al.sub.2O.sub.3, between
about 1% and about 2% S, between about 0.1% and about 1.5%
Fe.sub.2O.sub.3, between about 0.2% and about 1.0% MnO, and
incidental impurities. In a further embodiment, the slag 104 has a
composition including, by weight, of between about 5% and about 15%
MgO, between about 32% and about 42% SiO.sub.2, between about 7%
and about 16% Al.sub.2O.sub.3, between about 1% and about 2% S,
between about 0.1% and about 1.5% Fe.sub.2O.sub.3, between about
0.2% and about 1.0% MnO, a balance of CaO, and incidental
impurities.
[0039] In one embodiment, the slag 104 from the slag-producing
process 106 is coal slag and/or has a general composition
including, by weight, about 48% SiO.sub.2, about 10%
Al.sub.2O.sub.3, about 14% CaO, about 7.4% Fe.sub.2O.sub.3, about
6.2% MgO, about 1.6% Na.sub.2O, about 1.6% K.sub.2O, and incidental
impurities.
[0040] In one embodiment, the slag 104 from the slag-producing
process 106 is phosphate slag and/or has a general composition
including, by weight, about 16% to about 19% P.sub.2O.sub.5 (for
example, in the form 4CaO.P.sub.2O.sub.5.CaSiO.sub.3), about 4% to
about 12% MgO, a balance CaO, and incidental impurities. In another
embodiment, the slag 104 from the slag-producing process 106 is
phosphate slag and/or has a general composition including, by
weight, between about 39% and about 42% SiO.sub.2, up to about 3.5%
Al.sub.2O.sub.3, up to about 0.5% Fe.sub.2O.sub.3, up to about 2%
P.sub.2O.sub.5, a balance CaO, and incidental impurities.
[0041] In one embodiment, the slag 104 from the slag producing
process 106 is a steel slag and/or has a general composition
including, by weight, between about 10% and about 19% SiO.sub.2,
between about 1% and about 3% Al.sub.2O.sub.3, between about 5% and
about 10% MgO, between about 10% and about 40% Fe (for example,
from FeO or Fe.sub.2O.sub.3), between about 5% and about 8% MnO, a
balance CaO, and incidental impurities. In a further embodiment,
the slag 104 includes, by weight, between about 10% and about 19%
SiO.sub.2, between about 1% and about 3% Al.sub.2O.sub.3, between
about 5% and about 10% MgO, between about 10% and about 40% Fe (for
example, from FeO or Fe.sub.2O.sub.3), between about 5% and about
8% MnO, about 0.5% TiO.sub.2, between about 0.5% and about 1%
P.sub.2O.sub.5, a balance CaO, and incidental impurities.
[0042] In one embodiment, the slag 104 from the slag producing
process 106 is AOD slag and/or has a general composition including,
by weight, between about 6% and about 8% Al.sub.2O.sub.3, between
about 1% and about 3% Cr.sub.2O.sub.3, up to about 1%
Fe.sub.2O.sub.3, between about 0.5% and about 6% FeO, between about
4% and about 6% MgO, between about 22% and about 29% SiO.sub.2, a
balance CaO, and incidental impurities. In a further embodiment,
the slag 104 includes, by weight, between about 6% and about 8%
Al.sub.2O.sub.3, between about 1% and about 3% Cr.sub.2O.sub.3, up
to about 1% Fe.sub.2O.sub.3, between about 0.5% and about 6% FeO,
between about 4% and about 6% MgO, between about 0.8% and about 1%
MnO, between about 22% and about 29% SiO.sub.2, a balance CaO, and
incidental impurities.
[0043] In one embodiment, the slag 104 from the slag producing
process 106 is BOFS and/or has a general composition including, by
weight, between about 15% and about 35% FeO, between about 10% and
about 20% SiO.sub.2, up to about 10% Al.sub.2O.sub.3, up to about
10% MgO, up to about 10% MnO, up to about 2% P.sub.2O.sub.5, up to
about 2% Cr.sub.2O.sub.3, a balance CaO, and incidental
impurities.
[0044] In one embodiment, the agricultural blend 102 includes
silicon, calcium, and magnesium, for example, as a combination of
calcium silicate and magnesium silicate. In one embodiment, the
agricultural blend 102 further includes calcium between about 26
atomic % and about 28 atomic % and magnesium between about 6 atomic
% and about 8 atomic %, with the balance being other constituents
from the slag 104.
[0045] The agricultural blend 102 is capable of being in any
suitable form for delivery to plants, soil, or other agricultural
substances. In one embodiment, the agricultural blend 102 is
blended together, for example, by a high-speed blender 116. In one
embodiment, the agricultural blend 102 is a colloidal
suspension.
[0046] In one embodiment, the agricultural blend 102 is pelletized
or agglomerated, for example, by introducing a binder system 118 to
the agricultural blend 102 and pelletizing with a pelletizing disc
126 capable of varying speed and angle of rotation, thereby forming
a processed version of a pelletized agricultural blend 120. The
binder system 118 includes a property of promoting pellet strength
when used for forming agricultural pellets, includes a property of
promoting dispersion when used for blending agricultural binders,
includes a property of being compatible with calcium silicate,
includes other suitable properties, and combinations thereof.
[0047] In one embodiment, the agricultural blend 102 includes or is
formed using the binder system 118. The binder system 118 includes
a carbohydrate sugar, such as, beet juice, corn starch, molasses,
calcium citrate, condensed fermentation residual, soy polymer, or
combinations thereof, mixed with water. In one embodiment, the
carbohydrate sugar further includes protein.
[0048] The binder system 118 includes a predetermined volumetric
concentration of the carbohydrate sugar and the water. In one
embodiment, the predetermined volumetric concentration of the
binder system 118 includes between about 50 volume % and about 70
volume % being the carbohydrate sugar, between about 60 volume %
and about 70 volume % being the carbohydrate sugar, between about
50 volume % and about 60 volume % being the carbohydrate sugar,
between about 55 volume % and about 60 volume % being the
carbohydrate sugar, between about 50 volume % and about 55 volume %
being the carbohydrate sugar, about 50 volume % being the
carbohydrate sugar, about 55 volume % being the carbohydrate sugar,
about 60 volume % being the carbohydrate sugar, or combinations and
sub-combinations thereof.
[0049] In one embodiment, the binder system 118 is applied based
upon a predetermined weight concentration of the agricultural blend
102. In one embodiment, the carbohydrate sugar of the binder system
118 is between about 3 weight % and about 10 weight % of the
agricultural blend 102, between about 3 weight % and about 8 weight
% of the agricultural blend 102, between about 4.5 weight % and
about 10 weight % of the agricultural blend 102, between about 3
weight % and about 6 weight % of the agricultural blend 102,
between about 4 weight % and about 5 weight % of the agricultural
blend 102, greater than about 3 weight % of the agricultural blend
102, at about 4.5 weight % of the agricultural blend 102, or any
combination or sub-combination thereof.
[0050] Additionally or alternatively, in some embodiments, other
components, additives, micronutrient packets 130, sulfate sources
122, or combinations thereof are introduced to the agricultural
blend 102.
[0051] In one embodiment, the micronutrient packet 130 is added to
the agricultural blend 102 during the formation of the agricultural
blend 102 and/or after the formation of the agricultural blend 102.
In one embodiment, the micronutrient packet 130 includes boron,
copper, zinc, iron, manganese, and molybdenum. Additionally or
alternatively, in other embodiments, macronutrients (such as,
nitrogen, phosphorus, and/or potassium) and/or nutrients (such as,
calcium, magnesium, and/or sulfur) are added to the agricultural
blend 102. In one embodiment, the micronutrient packet 130, the
macronutrients, and/or the nutrients are added by a second
by-product (not shown) from a process, such as those described
above.
[0052] For example, in one embodiment, a nutrient such as sulfate
from the sulfate source 122 from a sulfate-producing process 124 is
added to the agricultural blend 102 during the formation of the
agricultural blend 102 and/or after the formation of the
agricultural blend 102.
[0053] In one embodiment, the agricultural blend 102 includes the
sulfate source 122 and calcium silicate. The sulfate source 122 can
be any suitable non-hazardous sulfate source including, but not
limited to, gypsum. The gypsum can be mined, synthetic, or a
combination thereof. Using mined gypsum, synthetic gypsum, and
combinations of mined gypsum and synthetic gypsum permits the
effects of the structure of the gypsum to be controlled and/or
adjusted.
[0054] The synthetic gypsum is from the sulfate-producing process
124 (such as, a portion of the slag-producing process 106 or
separate process). For example, in one embodiment, the
sulfate-producing process 124 forming the synthetic gypsum is a
by-product of flue gas desulfurization in a coal combustion
process. Additionally or alternatively, in one embodiment, the
sulfate source 122 is a by-product of other industrial processes.
For example, in one embodiment, the sulfate source 122 is a
by-product formed from slag in a coal combustion process, a
by-product formed from bottom-boiler ash in a coal combustion
process, a by-product formed from hydrogen sulfide produced from a
pickling liquor, or any suitable combination thereof.
[0055] In one embodiment, the composition of the agricultural blend
102 includes about 75 weight % to about 95 weight % being the
sulfate source 122 and about 5 weight % to about 25 weight % being
calcium silicate or the silicon-containing by-product 111 of the
slag 104. In one embodiment, the agricultural blend 102 includes
about 88.5 weight % being the sulfate source 122 and about 12.5
weight % calcium silicate or the silicon-containing by-product 111
of the slag 104. In one embodiment, a combined wet blend of the
agricultural blend 102 includes about 5 atomic % to about 6 atomic
% H.sub.2O, about 4 atomic % to about 6 atomic % magnesium, about
17 atomic % to about 19 atomic % sulfur, and a balance calcium. In
one embodiment, the combined wet blend includes about 5.6 atomic %
H.sub.2O, about 22.2 atomic % calcium, about 0.05 atomic %
magnesium, and about 17.5 atomic % sulfur. In one embodiment, a
combined dry blend of the agricultural blend 102 includes about 22
atomic % to about 26 atomic % calcium, about 0.04 atomic % to about
0.06 atomic % magnesium, and about 17.5 atomic % to about 19.5
atomic % sulfur. In one embodiment, the dry blend includes about
23.5 atomic % calcium, about 0.05 atomic % magnesium, and about
18.5 atomic % sulfur. In one embodiment, the pH of the agricultural
blend 102 can be about 7.5 to 8.5 or about 8.1. However, in another
embodiment, the pH is greater than 8.5 by including additional
ammonium sulfate as described below.
[0056] In one embodiment, the sulfate source 122 includes ammonium
sulfate. In this embodiment, ammonia is used as a reactant in the
sulfate-producing process 124 (such as, flue gas desulfurization in
coal combustion) to yield (NH.sub.4).sub.2SO.sub.4 (ammonium
sulfate). The pH of the resulting agricultural blend 102 is higher
than embodiments with the sulfate source 122 being from gypsum,
thereby permitting a blending to achieve a desired pH.
[0057] In one embodiment, the sulfate-producing process 124 is coal
combustion. Coal includes sulfur oxides (SOx). Monitoring emissions
in coal combustion involves monitoring whether SOx is being
emitted. To reduce SOx, various scrubbers or other systems remove
sulfur, sulfates, sulfites, sulfur trioxide, sulfur dioxide, or
other sulfur-containing compounds. The SOx reduced and/or removed
by flue gas desulfurization includes circulating of a flue gas to
remove sulfur from the flue gas and generating a sulfur-containing
by-product. There are two different methods of performing flue gas
desulfurization that produce the sulfate source 122. In a first
method (assuming ideal operating conditions), wet scrubbing is
performed with a CaCO.sub.3 slurry (for example, a limestone
slurry) to produce CaSO.sub.3 (calcium sulfite):
CaCO.sub.3 (solid)+SO.sub.2 (gas).fwdarw.CaSO.sub.3
(solid)+CO.sub.2 (gas) (1)
[0058] In a second method (assuming ideal operating conditions),
wet scrubbing is performed with a Ca(OH).sub.2 slurry (for example,
a lime slurry) to produce CaSO.sub.3 (calcium sulfite):
Ca(OH).sub.2 (solid)+SO.sub.2 (gas).fwdarw.CaSO.sub.3
(solid)+H.sub.2O (liquid) (2)
[0059] After the CaSO.sub.3 (calcium sulfite) is formed (either
under the first method or the second method), it undergoes a forced
oxidation process which converts it to the sulfate source 122,
CaSO.sub.4 (for example, synthetic gypsum):
CaSO.sub.3 (solid)+H.sub.2O (liquid)+1/2O.sub.2
(gas).fwdarw.CaSO.sub.4 (solid)+H.sub.2O (3)
[0060] In operation, the lime or limestone slurry is present with
the synthetic gypsum after the flue gas desulfurization. Depending
upon the concentration of sulfur in the coal and the other limiting
aspects of the reactions, the sulfate source 122 includes a
predetermined amount of synthetic gypsum and lime or limestone. In
one embodiment, the sulfate source 122 includes about 90 weight %
to about 95 weight % calcium sulfate (CaSO.sub.4.2H.sub.2O), about
1 weight % to about 2 weight % calcium sulfite
(CaSO.sub.3.1/2H.sub.2), and about 2 weight % to about 3 weight %
calcium carbonate (CaCO.sub.3). In one embodiment, the remaining
portion includes magnesium sulfate/sulfite.
[0061] In one embodiment, the sulfate source 122 is further
processed to achieve desired physical properties prior to being
introduced to the agricultural blend 102. For example, in one
embodiment, the sulfate source 122 is filtered through one or more
mesh stages. In one embodiment, 99% of the by-product is smaller
than #20 mesh, 90% of the by-product is smaller than #60 mesh, 75%
of the by-product is smaller than #100 mesh. Additionally or
alternatively, in one embodiment, moisture content of the sulfate
source 122 is adjusted to a predetermined range (for example, by
mechanical watering devices, filters, centrifuges, or combinations
thereof). In one embodiment, the predetermined range of moisture
content is between about 10% and about 18%, between about 10% and
about 15%, between about 7% and about 12%, between about 5% and
about 7%, or at about 5%. In one embodiment, the lime or limestone
forms about 90% to about 99% of the sulfate source 122. In another
embodiment, the gypsum forms about 90% to about 99% of the sulfate
source 122.
[0062] While the invention has been described with reference to a
preferred embodiment, it will be understood by those skilled in the
art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the invention. In addition, many modifications may be made to
adapt a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this invention, but that the invention will include
all embodiments falling within the scope of the appended
claims.
* * * * *