Slow-release fertilizer composition and preparation method

Abstract

A method of making the slow-release fertilizer and the composition thereof includes the steps of adding Class A Exceptional Quality biosolids at a percentage-by-weight of 35% to 75%, brewing grains at a percentage-by-weight of 10% to 50%, and dried algae at a percentage-by-weight of 5% to 20%. Biosolids are digested in an anaerobic digester for 15 days. Biosolids are dried to a moisture content under 6% and brewing grains and algae are dried to a moisture content under 10%. Algae is pressed to isolate the dried algae cell wall. The algae is dried to a moisture content under 10%. The Class A Exceptional Quality biosolids, brewing grains, and algae cell wall are pulverized to a mesh size between 100 to 300 and blended according to the above proportions.

Claims

1. A method of making a slow-release fertilizer composition comprising the steps of: a. adding biosolids at a percentage-by-weight of 35% to 75%; b. adding brewing grains at a percentage-by-weight of 10% to 50%; c. adding dried algae cell wall at a percentage-by-weight of 5% to 25%; d. blending the biosolids, the brewers grains, and the dried algae cell wall, and wherein at least 15% of a nutrient content of the composition becomes biologically active after administration of the composition.

2. The method of claim 1, including the step of digesting the biosolids in an anaerobic digester for 15 days.

3. The method of claim 1, including the step of dewatering the biosolids to a moisture content of 6% or less.

4. The method of claim 1, including the step of pulverizing the biosolids to a mesh size between 100 and 300.

5. The method of claim 1, including the step of dewatering the brewing grains to a moisture content of 10% or less.

6. The method of claim 5, including the step of drying the brewing grains at a temperature between 155 F. and 250 F.

7. The method of claim 1, including the step of pulverizing the brewing grains to a mesh size of 100 to 300.

8. The method of claim 7, including the step of treating the brewing grains with an oil based additive, wherein the oil based additive prevents billowing.

9. The method of claim 1, wherein the brewing grains are passed through a heating source per US EPA 40 CFR 503 Class A Exceptional Quality standards.

10. The method of claim 1, including the step of pressing algae to isolate the dried algae cell wall, wherein the dried algae cell wall is pulverized to a mesh size of 100 to 300, and wherein the dried algae cell wall is dried to a moisture content of less than 10%.

11. A composition of a slow-release fertilizer comprising: a. biosolids at a final percentage-by-weight of 35% to 75%; b. brewing grains at a final percentage-by-weight of 10% to 50%; c. dried algae cell wall at a final percentage-by-weight of 5% to 25%; wherein at least 15% of a nutrient content of the composition becomes biologically available after administration of the composition.

12. The composition of claim 11, wherein the biosolids are digested in an anaerobic digester for 15 days.

13. The composition of claim 11, wherein the biosolids are dewatered to a moisture content under 6%.

14. The composition of claim 11, wherein the biosolids are pulverized to a mesh size between 100 and 300.

15. The composition of claim 11, wherein the brewing grains are dewatered to a moisture content below 10%.

16. The composition of claim 15, wherein the brewing grains are dried at a temperature between 155 F. and 250 F.

17. The composition of claim 11, wherein the brewing grains are pulverized to a mesh size of 100 to 300.

18. The composition of claim 17, wherein the brewing grains are treated with an oil based additive, wherein the oil based additive prevents billowing.

19. The composition of claim 11, wherein the brewing grains are passed through a heating source per US EPA 40 CFR 503 Class A Exceptional Quality standards.

20. The composition of claim 11, wherein algae is pressed to isolate the dried algae cell wall, wherein the dried algae cell wall is pulverized to a mesh size of 100 to 300, and wherein the dried algae cell wall is dried to a moisture content of less than 10%.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) For a more complete understanding of the present invention, the objects and advantages thereof, reference is now made to the ensuing descriptions taken in connection with the accompanying drawings briefly described as follows.

(2) FIG. 1 is a flowchart of the method of production, according to an embodiment of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

(3) Preferred embodiments of the present invention and their advantages may be understood by referring to FIG. 1, wherein like reference numerals refer to like elements.

(4) In general, the invention described herein refers to a fertilizer composition and the method of production thereof. In an embodiment, biosolids, spent brewers grains, and algae cell wall are collected, treated, and mixed to specific ratios to form a slow release fertilizer. Slow release is defined as a fertilizer wherein a minimum of 15% of total nitrogen, potassium, and phosphorous is biologically unavailable at the initial application. Preferentially, biosolids are sourced from an Environmental Protection Agency (EPA) Class A exceptional quality rated facilities, with a pretreatment program in place to monitor any potential chemical inputs at concentrations that may be detrimental to soil and human health. To achieve exceptional quality status, the provider must not only meet, but exceed all standards for Class A biosolids including pathogen, metal, and vector attraction reduction parameters.

(5) Components of the composition are collected from one or more sources. Typically, components such as brewers grains and algae are received having a high moisture content that can result in rampant mold growth or decomposition, thus spoiling the component. To dry, a number of methods can be used as described herein. Heat, if used, is kept below 250 F. to prevent burning and to keep the total and available nutrients and compounds intact.

(6) In reference to FIG. 1, a method of preparation is illustrated in a preferred embodiment of the invention. Spent brewers grains comprising; malted barley, wheat, maize, corn, rice, sorghum, yeast, and millet, are collected from one or more sources and dried to a moisture content of 10% or less. The dewatering process can be accomplished by one or more ways as known in the art, such as centrifugation, heat, and evaporation. Once the desired moisture content is reached, the brewers grains are transferred to a storage bin such as a Super Sack to be transferred to a Super Sack unloading machine. Dried brewers grains are then conveyed via a screw auger into a pulverizer to render the dried grains into a fine powder, between 100-300 mesh size.

(7) Brewers grains typically arrive with a moisture content near 80%. In an embodiment, brewers grains are dewatered using any combination of the following: a centrifuge, a rotary drum, a heat exchanger, roaster, dehydrator, solar drying pad, or other tools known in the art. Drying of brewers grains must be done rapidly to avoid mold development and natural decomposition. Brewers grains should be prepared in this manner to maintain a moisture content is below 10%. In an embodiment, grains are pulverized to at least 100 mesh size and up to 300 mesh size to ensure even blending.

(8) In an embodiment, biosolid pellets are loaded into the super sack unloading machine and are then conveyed by screw auger into the pulverizer. The pulverized biosolids are conveyed to a separate super sack for storage prior to a blending stage.

(9) In an embodiment, manure and biosolids must meet the United States Environmental Protection Agencies (EPA) treatment standards for Class A Exceptional Quality. Further, manure is sourced from farms that allow animals free range and eating a natural diet. Biosolids are sourced from wastewater agencies that have 95% or greater residential customer base, and minimal toxic industrial and commercial customers. Per US Environmental Protection Agency 40 CFR 503 regulations for Class A Exceptional Quality biosolids, sewage sludge is digested in an anaerobic (digester) fermenter, moved to a centrifuge for dewatering, and transferred through a heat source to ensure pathogen reduction and elimination, uniform size, and dewatering. Final moisture content is 6% or less. Dried pellets are treated with a vegetable oil based additive to prevent billowing of dust when they are transported and moved between containers and spaces. The dried pellets are then pulverized to at least 100 mesh size and up to 300 mesh size powder to be blended into the final fertilizer composition.

(10) In an embodiment, a super sack containing dried algae cell wall is loaded into a super sack unloading machine and conveyed via a screw auger to a pulverizer. In an embodiment, dried algae are preprocessed to move through the screw auger without clogging. Pulverized algae are then conveyed into another super sack for storage prior to blending.

(11) In an embodiment, the algae is harvested from a system that captures carbon dioxide, soot, heat, and other exhaust from coal fired power plants, or other sources of burned biomass, mined materials, timber, or natural resources. In an embodiment, the algae are pressed to extract lipids, leaving the algae cell wall post lipid extraction, thus isolating the algae cell wall. The retained algae cell wall is dehydrated using processes known in the art such that nutrient content is preserved.

(12) Each of the super sacks containing the dried brewers grain, pulverized biosolids, and pulverized algae cell wall are loaded into weighing and proportioning equipment as known in the art. Each component is mixed uniformly, which is more easily accomplished due to the drying and pulverizing pretreatment. Once fully blended, fertilizer composition is placed in a super sack storage container before allocation into marketable volumes.

(13) In an embodiment, the final blend is comprised of biosolids at a range of 35% to 75% by weight, brewing grains at a range of 10% to 50% by weight, and dried algae cell wall at a range of 5% to 25% by weight.

(14) In preferred embodiment, the blend is comprised of; 55% EPA Class A exceptional quality biosolids, 30% dried brewers grains, and 15% dried algae cell wall. It is noted that this blend allows for faster metabolic breakdown and nutrient uptake by the crops. The specific blend, and mesh size of 100-300 allows for the composition to be utilized in a hydroponic system, wherein the composition is suspended in water and pumped through the hydroponic irrigation system.

(15) The invention has been described herein using specific embodiments for the purposes of illustration only. It will be readily apparent to one of ordinary skill in the art, however, that the principles of the invention can be embodied in other ways. Therefore, the invention should not be regarded as being limited in scope to the specific embodiments disclosed herein, but instead as being fully commensurate in scope with the following claims.