••
`
`Field of the Iuventioo
`
`Fortified Mulch
`
`The invention relates to a composition and method for making mulch fortified
`
`with fertilizers via an agglomeration/granulation process.
`
`Background of the Invention
`
`Mulches are commonly applied over grass seed beds. Mulches help to increase
`
`seed germination and decrease soil erosion allowing seeds to become firmly established
`
`in the seeded area. Mulches typically consist of straw, wood shavings, or paper. In the
`
`prior art mulches are mixed with water and agitated in a holding tank, and then sprayed
`
`onto a seed bed. Some mulches are woven into blankets that are designed to be laid
`
`down over seed beds. Some mulches are chemically bonded natural fiber spray-applied
`
`mulches. These mulches use a vegetable gum binder such as guar gum to bind together
`
`natural fibers.
`
`Most mulches are loose configurations of unbonded fibers that easily wash away.
`
`Paper-based mulches tend to bond into a paper mache-like mat that inhibits oxygen and
`
`sunlight transfer, and the ability of seedlings to emerge through the mulch, affecting
`
`vegetation establishment. Chemically-bonded mulch forms an almost impenetrable layer
`
`over the seed bed that is poor at passing oxygen and water through to the seed bed.
`
`U.S. Patent 5,942,029 discloses a mechanically-bonded, water-absorbent fiber
`
`mulch including natural and crimped synthetic fibers that are intimately mixed to fonn a
`
`mechanically-bonded fiber mulch.
`
`U.S. Patent 5,916,027 discloses mulch flakes made from finely divided paper
`
`and/or wood, and a surfactant. The flakes contain fertilizer.
`
`SCOTTS EXHIBIT 1013
`
`
`
`Field of the Iuventioo
`
`Fortified Mulch
`
`The invention relates to a composition and method for making mulch fortified
`
`with fertilizers via an agglomeration/granulation process.
`
`Background of the Invention
`
`Mulches are commonly applied over grass seed beds. Mulches help to increase
`
`seed germination and decrease soil erosion allowing seeds to become firmly established
`
`in the seeded area. Mulches typically consist of straw, wood shavings, or paper. In the
`
`prior art mulches are mixed with water and agitated in a holding tank, and then sprayed
`
`onto a seed bed. Some mulches are woven into blankets that are designed to be laid
`
`down over seed beds. Some mulches are chemically bonded natural fiber spray-applied
`
`mulches. These mulches use a vegetable gum binder such as guar gum to bind together
`
`natural fibers.
`
`Most mulches are loose configurations of unbonded fibers that easily wash away.
`
`Paper-based mulches tend to bond into a paper mache-like mat that inhibits oxygen and
`
`sunlight transfer, and the ability of seedlings to emerge through the mulch, affecting
`
`vegetation establishment. Chemically-bonded mulch forms an almost impenetrable layer
`
`over the seed bed that is poor at passing oxygen and water through to the seed bed.
`
`U.S. Patent 5,942,029 discloses a mechanically-bonded, water-absorbent fiber
`
`mulch including natural and crimped synthetic fibers that are intimately mixed to fonn a
`
`mechanically-bonded fiber mulch.
`
`U.S. Patent 5,916,027 discloses mulch flakes made from finely divided paper
`
`and/or wood, and a surfactant. The flakes contain fertilizer.
`
`SCOTTS EXHIBIT 1013
`
`
`
`Summary of the Invention
`
`The present invention relates to a process for creating fortified mulch through an
`
`agglomeration/granulation process. A moist paper fiber based product is impregnated
`
`with NPK (nitrogen, phosphorus, potassium) fortifiers in a mixer. The paper product is
`
`combined with the NPK fortifiers either before, or after entry into a mixer. The mixer
`
`performs work that results in an agglomerated (or granulated) product that is a
`
`homogeneous blend of the paper product and NPK fortifiers. This product is then dried
`
`to a desired level of moisture and screened as necessary. A binding agent can be added at
`
`the mixer to enhance the agglomeration/granulation process. If a binding agent is added
`
`the paper fiber based product need not be moist. To increase the percent of on-sized
`
`product, a size reduction operation can be performed on the paper fiber product prior to
`
`entry into the mixer.
`
`These and other features and advantages of the preferred embodiment of the
`
`present invention will become apparent from the detailed description of the preferred
`
`embodiments.
`
`Detailed Description of the Invention
`
`The present invention relates to a process for creating fortified mulch through an
`
`agglomeration/granulation process. A paper fiber based product, which can be moist, is
`
`impregnated with NPK fortifiers in a mixer. The mixer is preferably a pin mixer but can
`
`also be a pan pelletizer, paddle mixer, drum granulator or other type of mixer. The pin
`
`mixer is preferably a double helix pin arrangement. The paper fiber based product is
`
`preferably comprised of a by product of a paper making process. Sewage sludge can be
`
`used to create the fortified mulch rather than paper fibers.
`
`2
`
`
`
`Below is an example of how a fortified mulch product can be made using a pin
`
`•
`
`mixer.
`
`Example
`
`Pin Mixer
`
`In a pin mixer, agglomeration occurs, when radially extended pins mounted on a
`
`high velocity central rotor shaft, in a stationary cylindrical shell impart agitation forces on
`
`the material and sprayed liquid binder. This causes a tumbling, turbulent movement
`
`resulting in densification.
`
`Pin arrangement
`
`Several different types of pin mixers were tested to determine the best pin
`
`arrangement for creating a fortified mulch. The double helix pin arrangement resulted in
`
`a round, more uniform pellet. The internal casing length and diameter were 23 inches
`
`and 6 inches, respectively. The dimensions of the shaft and pins included 2-inch
`
`diameter shaft and two-inch length pins. The tip speed was not calculated. It was
`
`concluded that varying the speed (RPM) effected the pellet size. Increasing the speed
`
`caused a decrease in particle size. Also, the higher the speed (RPM) the fewer number of
`
`large chunks came through. It is important to note that initial ginding of wet paper
`
`sludge drastically reduced chunks discharging the pin mixer. It was found that the pin
`
`mixer when set at 650 RPM resulted in a product that consisted largely of end-size ( -6,
`
`+ 16) product. Although horsepower draws were not conducted, it was apparent that this
`
`material did not require a motor that was larger than FEECO pin mixer specifications.
`
`This material created a shell, but its amperage did not increase. Mulch through the pin
`
`mixer readily agglomerated and the discharged product was uniform in size and shape.
`
`3
`
`
`
`Retention Time
`
`The FEECO unit was inclined to analyze any improvement of product caused by
`
`an increased retention time. No increase in retention time was noticed. A test was
`
`conducted to determine the retention time of the. A scoop full of wet paper was spray-
`
`painted and fed into the feed hopper. Material began to discharge at 2 seconds and ended
`
`at 23 seconds. The majority of the material took 8 seconds. Small particles had short
`
`retention time while larger particles took longer.
`
`Pin Mixer; Material Feed Rates
`
`Ground wet paper sludge
`
`Wet paper was added at 33lbslhr the product was not uniform and round, so the
`
`feed was decreased to 200Jbs/h.r. A uniform product was achieved at this rate. It was
`
`preferable to use a rate of 200lbslhr, however, a rate between 200 and 3001bs.lhr is also
`
`acceptable. The wet paper sludge bridged in the screw feeder. The 3" feeder was the
`
`most consistent.
`
`Water
`
`An added 36-lbs./hr water was metered into the pin mixer. The percent moisture
`
`in the paper was 52.3% water. A total of 140.6lbs./hr of moisture is introduced when
`
`200lbs.lhr of wet sludge is metered into the pin mixer.
`
`NPK
`
`The NPK fortifiers were added to the pin at a rate of28 lbs.lhr. A vibratory
`
`feeder was required to feed such a low rate. The fertilizer had to be screened prior to
`
`addition into the feed hopper.
`
`4
`
`
`
`Coating Drum
`
`Wet Mulch Pellets
`
`The wet mulch pellets were hand fed into a rotary drum. The drum had no
`
`apparent problem with varied low or high feed rates. The rotatry dryer placed
`
`limiatations onto the coating drum feed rate. The majority (>90%) of agglomeration is
`
`done in the pin mixer. Since the material sent into the coating drum was in the form of a
`
`pellet, the material readily rolled. The retention time of the mulch was approximately 1-2
`
`minutes shorter than for an encapsulated seed (4-5 minutes).
`
`Dryer
`
`The pin mixer was not the only component limiting the feed rate, for the rota try
`
`dryer was not able to sufficiently dry the NPK fortified paper pellets. The increase in
`
`moisutre also forced the reduction in the feed rates.
`
`The inlet and outlet air temperatures were 1100 degrees Fahrenheit and 180F,
`
`respectively. The sample at these settings had a material outlet temperature ranging from
`
`150 to 175 degrees Fahrenheit and moisture content of2.5%.
`
`Sieve analysis
`
`A sieve analysis was conducted with the use of a screen. The end-size portion
`
`was between 6 and 16 mesh. A three-hour continuous run was produced, dried, and
`
`screened. The results concluded a total of300 lbs. of material; 206lbs. on-size (68.7%),
`
`53 lbs. under-size (17.7%), and 41 lbs. over-size (13. 7%).
`
`While the invention has been particularly shown and described with reference to
`
`the preferred embodiment of the present invention, it will be understood by those skilled
`
`5
`
`
`
`•
`
`in the art that the foregoing and other changes in form may be made therein without
`
`departing from the spirit and scope of the invention.
`
`6
`
`
`
`•
`
`~/An agglomeration/granulation method for creating a
`I
`
`adding paper fibers to a pin mixer;
`
`rtified mulch comprising;
`
`adding NPK fortifiers and a binding agent befi re or at said mixer;
`
`drying contents of said mixer.
`
`The method of claim 1 wherein the pin
`
`ixer is replaced with a pan pelletizer.
`
`The method of claim 1 whereiz;the
`
`·xer is replaced with a paddle mixer.
`
`The method of claim I wherei th pi
`
`ixer is replaced with a drum granulator.
`
`The method of claim 1 wher
`
`s ·
`
`in mixer has a double helix pin
`
`arrangement.
`
`The method of claim 1/erein said paper fibers are comprised of a by-product of
`
`a paper making process.
`
`The method of clai 1 wherein said paper fibers are replaced with sewage sludge.
`
`An agglomerate granulated mulch product that is comprised ofNPK fortifiers
`
`2.
`
`3.
`
`4.
`
`5.
`
`6.
`
`7. r
`
`7
`
`
`
`·•
`
`Abstract
`
`The invention relates· to a composition and method for making mulch fortified
`
`with fertilizers via an agglomeration/granulation process.
`
`8
`
`
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