Fertilizer compositions having slow-release nitrogen compounds and methods of forming thereof

1. A method of forming a fertilizer composition having slow-release nitrogen compounds, the method comprising:

forming a molten mixture of urea, formaldehyde, resin modifier, and one or more of a weak acid catalyst and an emulsifier; and

adjusting, as needed, the temperature of the molten mixture to initiate a reaction of the urea and the formaldehyde to form a fertilizer composition;

wherein the reaction of the urea and the formaldehyde occurs at an initial temperature of about 110° C. to about 125° C. and at a second temperature of about 125° C. to about 135° C.; and

wherein the initial temperature is held for about 10 minutes to about 40 minutes and wherein the second temperature is held for about 10 minutes to about 20 minutes.

2. The method of claim 1 , wherein the resin modifier comprises crystalline polyethylene wax and the emulsifier comprises a defoaming agent.

3. The method of claim 2 , wherein the defoaming agent comprises one or more of a star polymer defoaming agent and a fatty acid defoaming agent.

4. The method of claim 3 , wherein the fatty acid defoaming agent comprises polypropylene glycol ester and monoglycerides.

5. The method of claim 3 , wherein the molten mixture comprises about 500 parts-per-million (“ppm”) to about 2,000 ppm of star polymer defoaming agent and about 600 ppm to about 4,000 ppm of the fatty acid defoaming agent.

6. The method of claim 1 , wherein the weak acid catalyst has a pK a value of about 0.5 to about 5.0.

7. The method of claim 1 , wherein the weak acid catalyst comprises one or more of iodic acid, oxalic acid, chlorous acid, phosphoric acid, arsenic acid, chloroacetic acid, citric acid, hydrofluoric acid, nitrous acid, formic acid, and lactic acid.

8. The method of claim 1 , wherein the molten mixture comprises about 4.5*10 −5 moles to about 4.0*10 −3 moles of the weak acid catalyst per mole of formaldehyde.

9. The method of claim 1 , wherein the reaction of the urea and the formaldehyde occurs at a temperature of about 124° C. to about 127° C.

10. The method of claim 1 , wherein the mole ratio of urea to formaldehyde is about 2.4:1 or greater.

11. The method of claim 1 , wherein the resin modifier comprises a crystalline polyethylene wax comprising one or more of:

a molecular weight of about 600 to about 1,200;

a polydispersity of about 1.02 to about 1.7; and

a degree of crystallinity of about 65% to about 96%.

12. The method of claim 11 , wherein the molten methylene urea mixture comprises about 2% to about 20%, by weight, of the crystalline polyethylene wax.

13. The method of claim 1 , wherein the fertilizer composition comprises at least one of methylenediurea (“MDU”) and dimethylenetriurea (“DMTU”) and wherein the at least one of MDU and DMTU comprises about 35% or more of the total nitrogen in the fertilizer composition; and

wherein the fertilizer composition comprises about 8% or less cold-water insoluble nitrogen.

14. The method of claim 13 , further comprising the step of spray drying the fertilizer composition; and

wherein the fertilizer composition has a uniformity index after spraying of about 25 or greater.

15. The method of claim 13 , wherein the fertilizer composition is sprayed on an inert carrier to form a granule.

16. The method of claim 1 , wherein the fertilizer composition exhibits a peak storage modulus of about 2,000,000 Pa or less.

17. The method of claim 1 , wherein the molten mixture has a dynamic viscosity of about 0.3 Pa·s or less at a temperature of about 129.5° C.

18. The method of claim 1 is a continuous process.