We are delighted to share that MinTech was recently featured in the Innovation spotlight of California Business Journal.  Read on for a preview of the article.

DUST BUSTER

MinTech’s Unique Organic Dust Control Substances Reduce Airborne Dust by a Staggering 97 Percent

Before Harry Heydorn joined material-handling company MinTech, he worked as an engineer for a major coal-fired power utility company, where he faced a plague that became his business to eradicate: dust.

Every day, workers at the power plants moved coal out of the piles and conveyed it through the plant where it was crushed into a powder and then burned. They transferred tens of thousands of tons of coal an hour on conveyor belts moving 45 miles an hour, generating clouds of dust at every transfer point, and every time it was ground or pulverized.

Uncontrolled, most sources of dust in plants and mining operations lingers in the air, and is breathed into the lungs of workers, causing them major health problems such as silicosis and the infamous black lung disease.

“The main reason we’re eliminating and reducing dust is for the people, whether it’s the operators making the product, or somewhere downstream where there may be a transfer, or where they’re transloading materials, all the way down to the end users and any communities who could be affected,” Heydorn says.

MinTech recently launched MinTerra, a new and unique line of dust control solutions for the fertilizer industry, which like the coal industry, must manage the levels of dust created by material handling processes in order to protect workers and communities alike.

MinTerra DustAid helps reduce fertilizer dust by 97%

Read the entire article here: https://calbizjournal.com/dust-buster/.

Learn more about MinTech’s MinTerra solutions here: https://mintech.com/minterra/.

Soil management is a key part of agriculture Best Management Practices (BMPs), within which fertilizer application is vital to increasing crop yields and sustaining them at high levels.  Without it, the agricultural impact could be significant. One long-term field study based in Missouri found that 57% of grain yield resulted from lime and fertilizer application.  And another study found that corn yields could decline by 40% when fertilizer is not used[1].  If there’s an even greater nutrient deficit, that yield reduction could be more, having a severe impact on farm revenues and on meeting global food demand, which is expected to increase by at least 59% by 2050[2].

It’s easy to see that fertilizer plays a key role in boosting crop yield, driving farmer incomes, and feeding a growing population; however, applying fertilizer is not as straightforward or simple as it sounds.  There are many elements that can affect the efficacy of fertilizer, including even distribution during the application process.

Uniform fertilizer distribution is key to boosting crop yield.

Why uniform fertilizer application is important

Simply put, uniform fertilizer application is the only way to guarantee that vital nutrients are equally distributed to every crop.  Conversely, uneven application can cause irregular growth, discoloring among crops, decreased yield, and low crop value.

Uniform fertilizer application is not just a preference or a “nice to do” – it is key to proper soil management.

5 factors that affect even fertilizer distribution

There are five key factors that influence fertilizer application to a great degree.

1. Granule uniformity

Granule uniformity is a crucial contributor to quality fertilizer.  The importance of uniformity is twofold – it facilitates consistent nutrient distribution and even fertilizer application.

Granule uniformity is crucial: The more uniform the granules, the more likely they are to contain equal amounts of nutrients.

The more uniform the granules, the more likely they are to contain equal amounts of nutrients[3].  The less uniform the granule, the less predictable.  A 2005 study from the American Society of Agricultural and Biological Engineers[4] found that there was virtually no difference in the chemical makeup of fertilizer granules as long as they were the same size.

In addition to inconsistent nutrient make-up, when the granules are different shapes and sizes, the fertilizer doesn’t flow as easily, making an even spread more difficult to achieve.  Uneven distribution means some crops will receive nutrition while others are neglected.

Low uniformity is more likely to happen once fertilizer ages because the granules can degrade as they get older.  To improve the chances your fertilizer granules are uniform, use fertilizer as close to the date of manufacture as possible.  The closer the production date, the higher the likelihood the fertilizer will be in peak shape.  Also — though harder to control — purchasing fertilizer made from the same manufacturing batch is a great way to ensure consistency in the shape and size of your granules[5].

2. Caking and clumping

Caking is a sign that humidity has invaded your fertilizer.  Most farmers understand the downside of caked or clumped product – it’s less effective and, in many cases, its quality is compromised.  Should you need to apply caked fertilizer, an even spread is nearly impossible and can result in overfertilization and loss of important crop nutrients.

Caked fertilizer causes a buildup of residue in your fertilizer spreader, especially in spots like the spiral cones, the agitator, and the impeller.  This means that you’ll need to use more force to achieve the same volume of spread, and you’ll likely see a reduced delivery rate[6].  You’ll also need to recalibrate your spreader more frequently.  You may even need to use an abrasive or solvent to effectively remove the buildup.  All these issues result in additional time, resources, and financial costs and still do not ensure even fertilizer application.

3. Micronutrient/macronutrient segregation

In nutrient segregation, micronutrients and macronutrients are either unevenly bound or not bound to each other at all.  If unbound, the micronutrients often settle to the bottom of the product, so when the fertilizer is applied, the nutrients are not evenly distributed across the planting area.

There are three primary types of nutrient segregation[7]:

1. Ballistic segregation – The spreader tends to toss heavier granules further, which comes into play when the granules are blended from particles that are different sizes or weights.
2. Coning segregation – Heavy granules fall to the bottom of the fertilizer pile, so granules made from materials of different sizes, shapes, and densities are likely to separate.
3. Sifting segregation – Fertilizer sifting tends to happen during long periods of transport.

Regardless of the type of segregation, the unbinding of macronutrients and micronutrients leads to nutrient-deficient crops and lower yields.

4. Subsoil compaction

Compaction may help strengthen soil, but the more compacted it is, the more difficult it is to spread fertilizer evenly.  With a lot of compaction, fertilizer may not penetrate the soil[8] or reach all crops, as it bounces around and lands in random ways.  It’s critical that farmers assess this early on and address root-soil dynamics and nutrient movement to ensure the most even distribution possible.

5. Fertilizer spreader

The fertilizer spreader certainly plays an important role in even fertilizer application.  First, you need to choose the right spreader.  There are three main types to consider – rotary spreaders, drop spreaders, and liquid spreaders.  The one you decide on depends on the amount of land you need to cover and the type of fertilizer you are using.  Drop and liquid spreaders tend to work best for even, precise applications[9].   Rotary spreaders spread fertilizer over longer distances but do not follow any particular flow patterns.

Selecting the right spreader and using the right maintenance and application procedures directly impact successful fertilizer application.

After selecting the spreader, be sure to observe application best practices, such as using the right speed and gear for constant application, driving the correct working width, and heeding field margins to ensure you load enough fertilizer.  Also, regular maintenance is key to prevent buildup or breakdown of parts.

Conclusion

Uniform fertilizer distribution is one of the best ways to protect and improve your crop yield. While not all factors can be completely controlled, by taking the time to adhere to BMPs, manage your fertilizer quality, and maintain your spreader, you can help reduce unpredictable results.

MinTech can help, too.  The products in the MinTerra line are all designed to prevent the issues that make even application difficult.  DustAid controls fertilizer dust so product isn’t weakened or wasted, CakeBrake provides long-lasting anti-caking support, and MicroBind improves the durability and solubility performance of fertilizer blends.

Visit mintech.com/minterra/ to learn more.

[1] Mikkelsen, Rob. (2019). Understanding Fertilizer and Its Essential Role in High-Yielding Crops. Retrieved from: https://www.cropnutrition.com/understanding-fertilizer-and-its-essential-role-in-high-yielding-crops?7258dda8-3796-4e4a-aa05-5362a445b6ab=0

[2] Elferink, Maarten and Schierhorn, Florian. (April 7, 2016). Global Demand for Food Is Rising. Can We Meet It? Retrieved from: https://hbr.org/2016/04/global-demand-for-food-is-rising-can-we-meet-it

[3] Isleib, Jim (December 29, 2016). Pros and cons of granular and liquid fertilizers. Retrieved from: https://www.canr.msu.edu/news/pros_and_cons_of_granular_and_liquid_fertilizers

[4] Smith, D.B., Willcutt, M.H., and Diallo, Y. (2005). Uniformity Of Size And Content Of Granular Fertilizers. Retrieved from: https://elibrary.asabe.org/abstract.asp??JID=3&AID=18562&CID=aeaj2005&v=21&i=4&T=1

[5] Searle, Sam. (June 1, 2018). 5 Tips For Effective Fertiliser Spreading. Retrieved from: https://www.rataequipment.com/blog/5-tips-for-effective-fertiliser-spreading

[6] Parish, Richard L. (1998). Granular Spreaders: Selection, Calibration, Testing, and Use. Retrieved from: https://www.lsuagcenter.com/NR/rdonlyres/D9458BB7-D852-40B4-B434-5A6FC0C43E0E/3925/B868.pdf

[7] Simplot Partners. (2019). The Benefits of Homogeneous Granular Fertilizer. Retrieved from: http://partners.simplot.com/education/2018/03/08/benefits-of-homogeneous-granular-fertilizer

[8] Searle, Sam. (June 1, 2018). 5 Tips For Effective Fertiliser Spreading. Retrieved from: https://www.rataequipment.com/blog/5-tips-for-effective-fertiliser-spreading

[9] Framing Nailers Guide. (2019). 4 Types of Fertilizer Spreaders Explained by Real User. Retrieved from: https://framingnailersguide.com/types-of-fertilizer-spreaders/

MinTech chemists have conducted extensive tests to see if using our DustNot Syn product is as effective at curing the biomass pellet ails as it is the coal.  Spoiler Alert: It is.

Biomass pellet dust at vibratory feeder – before and after treatment

Here are the four common issues faced by biomass pellets:

1. The dried material is inherently dusty due to its organic powder/fiber composition
2. Angularity and high coefficient of friction (sCoF) causes abrasive and erosive material flow
3. Supply chain of biomass pellets has multiple transfers, each creating more and more dust
4. Biomass pellets are extremely absorbent, gaining moisture from the air, rain, snow, etc.
   • Reduction in caloric heat value (btu)
   • Degradation of pellet strength (most biomass binders are water-soluble)
   • Increased weight increases shipping costs

Watch the video below for a look at how much dust was generated at one transfer point in our field study prior to the application of DustNot Syn.  Keep this in mind because you’ll see the results at the bottom of this post.

MinTech set out to address each of these issues, first in the lab and then in the field, using DustNot Syn.  DustNot Syn is a synthetic, petroleum-free, food-grade dust control agent, made with proprietary technology.  The benefits of the product are numerous:

• Provides residual dust control for up to 180 days
• Operating temperature from -40°C to +60°C (-40°F to +140°F)
• Designed for water-sensitive materials like lignin, cellulose, wood, and fertilizer
• Environmentally responsible
  • Petroleum-free, metal-free,
  • No VOCs (volatile organic compounds)
  • Non-toxic, non-corrosive, non-flammable
  • Odorless, colorless, food-grade, and allergen-free
  • No phosphates, chlorides, EDTA, APE, or NPE compounds
• Non-leaching, and provides a clear, water-resistant coating to pellets
• Non-filming, non-crusting, and never dries out
• No ash or emission concerns at power stations – has been used to treat coal, limestone, pet coke, and other fuels
• High BTU value of 140,000 Btu/gallon (142,425 kJ)
• Provides lubricity to pellets, reducing friction, improving flow, and reducing degradation

Our preliminary lab tests showed that DustNot Syn reduced dust by 95%.

Photo of third-party preliminary lab test results.

We then took the product to the field and tested six different application methods to determine the optimum process to achieve the highest, most consistent level of control.  The results are in:

• DustNot Syn provides a 90% reduction in dust
  • Degree of control dependent upon treatment rate and application technique
• DustNot Syn protects biomass pellets from moisture ingression
  • Untreated biomass pellets absorbed 5X more water than treated pellets
• DustNot Syn’s performance improves with multiple transfers of pellets
• DustNot Syn controls dust for at least 45 days

Now watch this video of just how much dust was abated by the use of DustNot Syn at transfer.  That’s what I call results!

To download the full study, click here.

If you are interested in learning more about how MinTech can help you with your biomass process, please contact us.