WO2024259082A1 - Fertilizer composition comprising bioash and stillage or digestate, bioprocessing facility and method of obtention - Google Patents

Abstract

Fertilizer compositions made mixing at least one bio-ash composition and at least one composition chosen from at least one stillage composition, at least one anaerobic digestion digestate composition, and combinations thereof, to form the fertilizer composition.

Description

FERTILIZER COMPOSITION COMPRISING BIOASH AND STILLAGE OR DIGESTATE, BIOPROCESSING FACILITY AND METHOD OF OBTENTION

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This patent application claims the benefit of U.S. Provisional Patent Application Serial Number 63/521,295, filed on June 15, 2023, wherein said provisional patent application is incorporated herein by reference in its entirety.

BACKGROUND

[0002] The present disclosure relates to fertilizer compositions and methods of making fertilizer compositions. There is a continuing need for new methods of making fertilizer compositions and/or new fertilizer compositions.

SUMMARY

[0003] The present disclosure includes embodiments of a method of making a fertilizer composition. The method includes mixing at least one bio-ash composition and at least one composition chosen from at least one stillage composition, at least one anaerobic digestion digestate composition, and combinations thereof, to form the fertilizer composition.

[0004] The present disclosure also includes embodiments of a facility. The facility includes a bioprocessing facility configured to generate at least one composition chosen from at least one stillage composition, at least one anaerobic digestion digestate composition, and combinations thereof. The facility also includes at least one thermal energy generating system configured to generate thermal energy for the bioprocessing facility and produce a bio-ash composition via a combustion process. The bioprocessing facility is configured to use at least a portion of the thermal energy in one or more systems in the bioprocessing facility. The facility also includes a fertilizer composition production system that is co-located with the bioprocessing facility. The fertilizer composition production system is in fluid communication with the bioprocessing facility to receive at least a portion of the at least one composition. The fertilizer composition production system is in fluid communication with the at least one thermal energy generating system to receive at least a portion of the bio-ash composition. The fertilizer composition production system is configured to mix the at least a portion of the bio-ash composition and the at least a portion of the at least one composition to form the fertilizer composition.

[0005] The present disclosure also includes embodiments of a fertilizer composition that includes discrete units. Each discrete unit includes a mixture of at least one bio-ash composition and at least one composition chosen from at least one stillage composition, at least one anaerobic digestion digestate composition, and combinations thereof.

[0006] The present disclosure also includes embodiments of a fertilizer composition that includes a mixture of at least one bio-ash composition and at least one composition chosen from at least one stillage composition, at least one anaerobic digestion digestate composition, and combinations thereof. The fertilizer composition has a carbon (C): nitrogen (N) ratio in a range from 2: 12 (e.g., from 3: 10, from 4:9, or even 5:8) to 1 : 1.

[0007] The present disclosure also includes embodiments of a method of making a fertilizer composition. The method includes forming a fertilizer composition into discrete units. The fertilizer composition includes at least one composition chosen from at least one bio-ash composition, at least one stillage composition, at least one anaerobic digestion digestate composition, and combinations thereof.

[0008] The present disclosure also includes embodiments of a fertilizer composition that includes discrete units. Each discrete unit includes a composition chosen from at least one bio-ash composition, at least one stillage composition, at least one anaerobic digestion digestate composition, and combinations thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Various examples of the present disclosure will be discussed with reference to the appended drawings. These drawings depict only illustrative examples of the disclosure and are not to be considered limiting of its scope.

[0010] FIG. 1 shows a process-flow graphic of a non-limiting embodiment of a bioprocessing facility co-located and integrated with a fertilizer composition production system configured to form a fertilizer composition according to the present disclosure;

[0011] FIG. 2 shows a non-limiting example of equipment (pan granulator) that can be used form a fertilizer composition into discrete units according to the present disclosure;

[0012] FIG. 3A shows a process-flow diagram of a non-limiting embodiment of a dry-grind corn ethanol bioprocessing facility configured to form a plurality of stillage compositions; and

[0013] FIG. 3B shows a process-flow diagram of a non-limiting embodiment of the com oil separation system shown in FIG. 3 A.

[0014] FIG. 4 is a graph that shows the results of an experiment in Example 1;

[0015] FIG. 5 is a photograph of pellets formed in Example 2; and [0016] FIG. 6 is a photograph of pellets formed in Example 3. DETAILED DESCRIPTION

[0017] There is a continuing need for new methods of making fertilizer compositions and/or new fertilizer compositions. For example, there is a continuing need to replace mined minerals used to make fertilizer compositions.

[0018] A “fertilizer composition” according to the present disclosure includes at least one composition chosen from at least one bio-ash composition, at least one stillage composition, at least one anaerobic digestion digestate composition, and combinations thereof.

[0019] In some embodiments, the present disclosure includes methods of making a fertilizer composition by mixing at least one bio-ash composition with at least one stillage composition and/or at least one anaerobic digestion digestate composition to form a fertilizer composition. Advantageously, using such components to make a fertilizer may reduce carbon intensity of farming.

[0020] As used herein, a “bio-ash composition” refers to an ash derived from the combustion of biomass to produce a flue gas and a bio-ash composition. While the bio-ash composition can be considered a waste product that needs to be disposed, the present disclosure involves using the bio-ash composition to make a fertilizer composition because of the nutrient value in the bio-ash composition, thereby creating a stream of revenue. Also, in some embodiments, using the bio-ash composition to make a fertilizer composition can help utilize the biomass from which is was derived in a circular manner by applying it to a field to grow more biomass.

[0021] A bio-ash composition can be selected to make a fertilizer composition based on one or more properties such as nutrient profile, pH, average particle size, nutrient release properties, combinations of these, and the like.

[0022] A bio-ash composition can include nutrients suitable for plant nutrition such as one or more macronutrients, one or more micronutrients, and combinations thereof. A bio-ash composition may include one or more nutrients in sufficient quantities for plant nutrition. It is noted that the bioavailability of a nutrient to a plant can depend on the chemical form that the nutrient is in. As used herein, “bioavailability” refers to the fraction of the total mass of an element or compound that a nutrient is in that has the potential for uptake by one or more plants and/or one or more microbes in soil that one or more plants are growing. In some embodiments, a bio-ash composition can be supplemented to provide an additional quantity of one or more nutrients. Plant macronutrients include mineral nutrients such as nitrogen (N), phosphorus (P), potassium (K), calcium (C), sulfur (S), magnesium (Mg), carbon (C), oxygen (O), and hydrogen (H). Plant micronutrients include trace mineral nutrients such as iron (Fe), boron (B), chlorine (Cl), manganese (Mn), zinc (Zn), copper (Cu), molybdenum (Mo), and nickel (Ni). The content of one or more nutrients in a bio-ash composition can be determined by nutrient analysis via one or more of calorimetric testing, extraction testing, and the like. [0023] Nitrogen is a macronutrient that is a major constituent of several plant components, and can be a limiting nutrient for plant growth. In fertilizer compositions, nitrogen can be reported in terms “total nitrogen,” which is the sum of all forms of nitrogen and can be described as total nitrogen = ammonia nitrogen (NH3) + organic nitrogen (nitrogen in amino acids and proteins, which includes urea and uric acid) + nitrite (NO2) + nitrate (NO3). In some embodiments, a bio-ash composition has a total nitrogen content of 0.1% or greater, 0.2% or greater, 0.3% or greater, or even 0.4% or greater by total weight of the bio-ash composition.

[0024] Phosphorus is a macronutrient that is another major constituent of several plant components, and can be a present in organic and inorganic forms. In fertilizer compositions, the available phosphorus can be reported in terms of “phosphate (P2O5)” content, which is often used interchangeably with elemental phosphorus (P) in soil science and fertilizer science. Phosphorus pentoxide (P2O5) is also referred to as diphosphonate, which is a divalent inorganic anion obtained by remove of both protons from diphosphonic acid. Phosphorus pentoxide (P2O5) is a crystal form that occurs in soil. Phosphorus (P) is actually taken up by plants in the form of phosphate compounds such as dihydrogen phosphate [H2PO4]² and/or hydrogen phosphate [HPCh]'. In some embodiments, a bio-ash composition has a phosphate (P2O5) content of 0.5% or greater, 1% or greater, 1.2% or greater, or even 1.3% or greater by total weight of the bio-ash composition.

[0025] Potassium is a macronutrient that is present in many parts of a plant and can play a role in plant functions such as enzyme activity. A fertilizer composition can include one or more sources of potassium that can be incorporated by a plant. Non-limiting examples of source of potassium in a fertilizer composition include monopotassium phosphate, potassium chloride (muriate of potash), potassium hydroxide solution, potassium nitrate, potassium thiosulfate, potassium sulfate (sulfate of potash), potassium magnesium sulfate (sulfate of potash magnesia), and combinations thereof. In fertilizer compositions, although plants do not take up potassium oxide (K2O) and fertilizer compositions typically do not include K2O, the potassium content in a fertilizer composition can be reported in terms of K2O (or K2O equivalent). In some embodiments, a bio-ash composition has a potassium oxide (K2O) equivalent content of 1% or greater, 2% or greater, 3% or greater, 4% or greater, 5% or greater, or even 6% or greater by total weight of the bio-ash composition. [0026] Carbon forms a backbone of many plant biomolecules including proteins, starches, and cellulose. Although carbon can be obtained by a plant from carbon dioxide in the air, including carbon in a fertilizer composition can help provide carbon for microbial growth in the soil. The bioavailability of carbon can vary from material to material. For example, the bioavailability of carbon present in cellulose can vary depending on how resistant the cellulose is to microbial degradation. As discussed below, carbon tends to be consumed to a relatively high degree during the combustion of biomass. Whether carbon in a bio-ash composition is available for microbial consumption depends on the bioavailability of the form of carbon that is present in a bio-ash composition. As discussed below, in some embodiments, a bio-ash composition can be combined with one or more supplemental sources of carbon to form a fertilizer composition. In fertilizer compositions, the carbon content can be reported in terms of “total carbon.” Total carbon is the combined amount of inorganic and organic carbon. One method of determining total carbon content is by using a laboratory elemental analyzer to analyze a sample of bio-ash composition. In some embodiments, a bio-ash composition has a total carbon content of 5% or less, 4% or less, 3% or less, or even 2% or less by total weight of the bio-ash composition. In some embodiments, a bio-ash composition has a total carbon content in a range from 0.1% to 5%, from 0.5% to 4%, or even from 1% to 3% by total weight of the bio-ash composition.

[0027] A bio-ash composition tends to have a pH greater than 7. In some embodiments, a bio-ash composition has a pH of 10 or greater, 11 or greater, or even 12 or greater.

[0028] A bio-ash composition is produced via combustion of biomass that results in solid ash powder. In some embodiments, the solid ash powder can accumulate at the bottom of a combustion chamber (bio-ash bottoms ash) and/or be present as entrained powder (bio-ash fly ash) in flue gas. A bio-ash composition can be recovered from flue gas. Non-limiting examples of recovering bio-ash fly ash from a flue gas include filtration (e.g., a fabric baghouse), electrostatic precipitation, and combinations thereof.

[0029] The average particle size of a bio-ash composition can depend on a variety of factors such as the biomass and/or the form of the biomass that is used in combustion. In some embodiments, the average particle size of a bio-ash composition can vary among the bio-ash fly ash and bio-ash bottoms ash. The particle size of a bio-ash composition can influence one or more of nutrient bioavailability, mixing with one or more liquid components, and formation of discrete units (e.g., pellets). In some embodiments, a bio-ash composition has an average particle size of 200 microns or less, 175 microns or less, 150 microns or less, 125 microns or less, or even 100 microns or less. In some embodiments, a bio-ash composition has an average particle size from 100 to 150 microns.

[0030] In some embodiments, the average particle size of a bio-ash composition can be adjusted as desired, e.g., to make nutrients relatively more available to a plant and/or to improve formation of discrete units (e.g., to facilitate granulation and/or make the discrete units more durable/stable). Adjusting the average particle size of a bio-ash composition can be performed via one or more of blending two or more bio-ash compositions having different average particle sizes, particle size reduction (e.g., via grinding), and the like.

[0031] A bio-ash composition can be produced by exposing biomass to one or more combustion conditions to generate heat and form solid ash powder. In some embodiments, one or more combustion conditions can be selected to generate energy as the primary goal. Under such conditions, carbon tends to be consumed to a relatively high degree such that the resulting ash tends to have a relatively very low carbon content as compared to the biomass prior to combustion. Also, under such conditions, nutrient content in the form of minerals tends to be concentrated in the resulting ash as compared to the biomass prior to combustion. Non-limiting examples of combustion conditions include oxygen source for combustion, combustion temperature, and the like. The combustion temperature can influence the bioavailability of one or more nutrients in the ash. For example, as the combustion temperature increases, one or more nutrients in the ash can be relatively less available for uptake by a plant. In some embodiments, the combustion temperature can be from 300 to 600°C. The oxygen content provided to the combustion process can also influence the chemical composition of the ash and/or the bioavailability of one or more nutrients in the bioash composition. For example, as the oxygen content provided to combustion increases, one or more nutrients can be relatively more available in the bio-ash composition. In some embodiments, oxygen can be provided to combustion via air (which is about 21% oxygen). In some embodiments, a relatively higher concentration of oxygen can be provided to combustion. In some embodiments, combustion conditions include those used for a typical solid-fuel boiler designed to generate energy. In some embodiments, the combustion conditions will be selected based on generating energy only and not necessarily for one or more properties of the resulting bio-ash composition. A fertilizer composition according to the present disclosure can be formulated taking into account whatever bio-ash composition is formed by a solid-fuel boiler.

[0032] For illustration purposes, biomass can be burned at a bioprocessing facility to generate energy for the bioprocessing facility. As used herein, a bioprocessing facility refers to a facility that can produce one or more bioproducts by converting biomass feedstock via one or more physical processes, one or more chemical processes, one or more bioprocesses, and combinations thereof. Non-limiting examples of bioprocessing facilities include dry mills, wet mills, biofuel production facilities, anaerobic digestion facilities, pharmaceutical production facilities, soy processing facilities, breweries, bakeries, and the like. A bioproduct refers to a product derived from a biological, renewable resource. For example, a bioproduct can be a component of biomass feedstock that is liberated from the biomass feedstock (e.g., corn oil from com grain) and/or can include a chemical (“biochemical” or “ target biochemical”) that is produced by a biocatalyst (e.g., microorganism and/or enzyme) such as, for example, alcohol produced by yeast fermenting sugar. Non-limiting examples of bioproducts produced in a bioprocessing facility include one or more of fuel, feed, food, pharmaceuticals, beverages and precursor chemicals. In some embodiments, a bioproduct includes, among others, one or more monomeric sugars, one or more enzymes, one or more oils, one or more alcohols (e.g., ethanol, butanol, and the like), fungal biomass, amino acids, and one or more organic acids (e.g., lactic acid), and combinations thereof.

[0033] In some embodiments, biomass can be burned as solid fuel in a steam boiler system and/or in a power generation system at a bioprocessing facility. A steam boiler system can generate steam using heat from the combustion of biomass. A power generation system can generate electricity using a steam turbine system that receives steam from a steam boiler system. Non-limiting examples of steam turbine systems include condensing turbine systems, non-condensing turbine systems, reheat turbine systems, extracting turbine systems, and combinations thereof.

[0034] A wide variety of biomass can be used to generate a bio-ash composition according to the present disclosure. In some embodiments, the biomass used to generate a bio-ash composition is the same as biomass feedstock used in a bioprocessing facility to form a bioproduct as discusses above. In some embodiments, the biomass used to generate a bio-ash composition is different from the biomass feedstock used in a bioprocessing facility to form a bioproduct as discusses above. In some embodiments, a bio-ash composition is derived from combustion of one or more plant-based feedstocks. Non-limiting examples plant-based feedstocks that can be used as fuel in combustion and form a bio-ash composition include crop residues (e.g., husks, stems, com stover, wheat straw), grasses, straw, woody plants (firewood), waste wood (e.g., storm wood, pallets, trimmings from lumber processing operations, and the like), bioprocessing residue (e.g., bran, whole stillage, wet cake, sugarcane bagasse, pulp, and the like) derived from sugar beets, sugar cane, grains, legumes, corn, sorghum, wheat, rice, barley, soybean, rapeseed, oats, oat hulls, millet, rye, and the like, and/or bio-char produced from one or more of the aforementioned plant-based feedstocks. In some embodiments, a bio-ash composition is derived from combustion of municipal waste. [0035] A plant-based feedstock can be processed prior to combustion as desired. For example, a plant-based feedstock such as a bale of straw or corn stover could be simply unbaled and fed into a solid-fuel boiler. As another example, a plant-based feedstock can be dried to reduce its moisture content. As another example, the plant-based feedstock can be size-reduced to increase its surface area to volume area for combustion purposes.

[0036] For illustration purposes, Table 1 includes compositional data for bio-ash fly ash from burning wood and bio-ash fly ash from burning corn stover. The bio-ash fly ash from burning wood included burning wood pallets (obtained from Mueller Pallets, Sioux Falls, SD) and tree waste in a solid fuel boiler at an ethanol plant.

[0037] In some embodiments, at least one bio-ash composition can be mixed with at least one stillage composition and/or at least one anaerobic digestion digestate composition to form a fertilizer composition. Thereafter, the fertilizer composition can be directly applied to a soil or may be further processed before being applied to soil.

[0038] As used herein, a “stillage composition” refers to a back-end composition of a fermentation process after separating (e.g., via distillation) one or more bioproducts from beer to form at least one target bioproduct stream (e.g., ethanol) and one or more co-product streams (e.g., whole stillage). A stillage composition can include whole stillage, at least one stillage composition derived from whole stillage, and combinations thereof. Non-limiting examples of a stillage composition derived from whole stillage include thin stillage, concentrated thin stillage (syrup), defatted syrup, defatted emulsion, clarified thin stillage, distiller’s oil, distiller’s grain, distiller’s yeast, and the like. Defatted syrup and defatted emulsion are examples of stillage compositions that remain after fat (e.g., corn oil) has been separated from syrup and emulsion, respectively, and each can be referred to as a “defatted stillage composition.” Non-limiting examples of methods and systems for processing stillage streams are described in U.S. Pat. No. 8,702,819(Bootsma); U.S. Pat. No. 9,061,987(Bootsma); U.S. Pat. No. 9,290,728(Bootsma); U.S. Pat. No. 10,059,966 (Bootsma); U.S. Pat. No. 11,248,197 (Bootsma); and U.S. Pub. No. 2020/0140899 (Bootsma); wherein the entirety of each of said patent documents is incorporated herein by reference.

[0039] FIG. 3A illustrates an example of dry-grind corn ethanol biorefinery as a bioprocessing facility 300 that produces stillage compositions described above. The bioprocessing facility 300 includes a “front end” and a “back end.” The front end includes distillation 305 and upstream from distillation 305. As shown in FIG. 3A, the front end starts with adding ground corn and water 301 to a slurry tank 302, which is fed to a fermentation system 303 that ferments sugars into a beer that includes ethanol and carbon dioxide. Beer is transferred to a beer well 304 and eventually to a distillation system 305 where ethanol 307 is separated from beer to form whole stillage 306.

[0040] Whole stillage 306 is fed to decanter 330 to separate whole stillage 306 into wet cake 332 and thin stillage 355. The wet cake 332 and syrup 359 is dried in dryer system 360 to form dried distillers’ grain with solubles (DDGS).

[0041] A portion 326 of the thin stillage 355 is transferred to the slurry tank 302 as backset, while the rest 327 of the thin stillage 355 is transferred to an evaporation train 329 that may include 4 to 8 evaporators in series (depending on plant size) to remove water and form syrup 359. Prior to reaching the end of the evaporator train 329, a semi-concentrated syrup (“skim feed”) 371 is removed and sent to com oil separation system 370 which removes corn oil product 392.

[0042] The corn oil separation system 370 is described in more detail using FIG. 3B. As shown in FIG. 3B, the skim feed 371 is separated in a “skim” centrifuge 373 into an emulsion 378 and defatted syrup 374. The defatted syrup 374 can accumulate in defatted syrup tank 375 and defatted syrup 374 is eventually returned to the evaporator train 329 via pump 377, where a final syrup 359 is sent to dryer 360 to form DDGS 361 as shown in FIG. 3A. The emulsion 378 is combined with caustic 382 in emulsion tank 380 to help “break” the emulsion into an oil phase and aqueous phase that are more easily separated from each other. The treated emulsion 384 is pumped via pump 383 to oil centrifuge 386, wherein the treated emulsion 384 is separated into a com oil product 392 and defatted emulsion 388. The defatted emulsion 388 can accumulate in defatted emulsion tank 389 and defatted emulsion 388 can be pumped via pump 390 to any desired location. The skim centrifuge 371 and oil centrifuge 386 can be disk-stack centrifuges.

[0043] A stillage composition can be selected and combined and mixed with a bio-ash composition based on a variety of factors such as processing properties when forming, storing, and/or transporting a fertilizer composition, forming discrete units, application properties when applying a fertilizer composition to soil, and/or product properties after the fertilizer composition has been applied to soil.

[0044] In some embodiments, the viscosity of a mixture can be adjusted (increased or decreased) using a stillage composition so that the mixture can be processed in equipment to make discrete units. In some embodiments, the viscosity of a mixture can be adjusted (increased or decreased) using a stillage composition so that a fertilizer composition can be processed in equipment (e.g., through a sprayer) to apply the fertilizer composition to soil. [0045] If desired, the nutrient profile of fertilizer composition can be adjusted using a stillage composition. In some embodiments, a stillage composition may contribute an additional amount of one or more nutrients as compared to that provided by a bio-ash composition and/or an anaerobic digestion digestate composition. In some embodiments, a stillage composition may reduce the concentration of one or more nutrients or elements (dilute) as compared to what is present in a bio-ash composition. For example, sodium present in bioash composition may be present at a concentration that is undesirable for one or more plants and/or soil microbes when included in a fertilizer composition. One or more stillage compositions may be incorporated into the fertilizer compositions to dilute the sodium concentration to an acceptable level. In some embodiments, a stillage composition may provide additional carbon (C) in the fertilizer composition, which can be especially useful for soil microbe health and to the benefit of an agricultural crop. As discussed above, carbon tends to be consumed to a relatively high degree during the combustion of biomass and form a bio-ash composition. According to the present disclosure, one or more stillage compositions can be combined with a bio-ash composition to form a fertilizer composition, and used as a supplemental source of carbon for soil microbes depending on the bioavailability of carbon in a given stillage composition. [0046] In some embodiments, a stillage composition may be selected for providing desirable binding properties for discrete units so that the discrete units do not degrade to an undue degree during one or more of processing, storage, transportation, or application to soil, while at the same time degrading in a desirable manner after being applied to soil. Providing binding properties to a bio-ash composition can be advantageous. For example, a bio-ash composition can be relatively light and fluffy, which can make it difficult to apply to a soil so that it remains in place without blowing away due to wind. In some embodiments, a stillage composition can make a fertilizer composition formed from a bio-ash composition and the stillage composition relatively denser so that the fertilizer composition does not blow around to an undue degree after being applied to soil. The pH of a stillage composition can affect the bioavailability of one or more nutrients in a fertilizer composition formed therefrom. The pH of a stillage composition can vary but tends to be acidic. In some embodiments, a stillage composition can have a pH of 6.5 or less, 6 or less, 5.5 or less, 5 or less, 4.5 or less, 4 or less, or even 3.5 or less. The pH of a stillage composition may or may not be adjusted when forming a fertilizer composition. For example, mixing a highly acidic composition and a highly basic composition can be an exothermic process, which may be undesirable. In some embodiments, if an acidic stillage composition is to be combined with a component that has a relatively high pH (e.g., a bio-ash composition having a pH of 12 or greater), the pH of the acidic stillage composition may be increased to reduce the difference in pH prior to combining the stillage composition with the component that has a relatively high pH. [0047] For illustration purposes, Table 1 includes compositional data for three stillage compositions: syrup (concentrated thin stillage); defatted syrup; and distillers’ dried grain with solubles (DDGS).

[0048] As used herein, an “anaerobic digestion digestate composition” refers to one or more effluent compositions discharged from, or derived therefrom, an anaerobic digestion process that breaks down organic matter via bacteria in the absence of oxygen to produce biogas, which is a mixture of methane, carbon dioxide, hydrogen sulfide, water vapor, and trace amounts of other gases. Non-limiting examples of organic matter that can be fed to an anaerobic digestion process include at least one of one or more manure compositions, one or more food waste compositions, one or more energy crops, one or more crop residues, one or more stillage compositions (e.g., thin stillage and/or syrup and/or defatted syrup), one or more fats, one or more oils, and the like. Effluent compositions discharged from an anaerobic digestion process include anaerobic digestion liquid effluent, anaerobic digestion solid effluent, and combinations thereof. Organic nitrogen may be converted to ammonia during anaerobic digestion and be present in an anaerobic digestion digestate composition. If desired the ammonia may be separated from the anaerobic digestion digestate composition via distillation and the like. The separated ammonia can be relatively more concentrated and can be used in making a fertilizer composition according to the present disclosure.

[0049] Like a stillage composition discussed above, an anaerobic digestion digestate composition can be selected and combined and mixed with a bio-ash composition based on a variety of factors such as processing properties when forming, storing, and/or transporting a fertilizer composition, forming discrete units, application properties when applying a fertilizer composition to soil, and/or product properties after the fertilizer composition has been applied to soil.

[0050] In some embodiments, the viscosity of a mixture can be adjusted (increased or decreased) using an anaerobic digestion digestate composition so that the mixture can be processed in equipment to make discrete units. In some embodiments, the viscosity of a mixture can be adjusted (increased or decreased) using an anaerobic digestion digestate composition so that a fertilizer composition can be processed in equipment (e.g., through a sprayer) to apply the fertilizer composition to soil.

[0051] If desired, the nutrient profile of fertilizer composition can be adjusted using an anaerobic digestion digestate composition. In some embodiments, an anaerobic digestion digestate composition may contribute an additional amount of one or more nutrients as compared to that provided by a bio-ash composition and/or a stillage composition. In some embodiments, an anaerobic digestion digestate composition may reduce the concentration of one or more nutrients or elements (dilute) as compared to what is present in a bio-ash composition. For example, sodium present in bio-ash composition may be present at a concentration that is undesirable for one or more plants and/or soil microbes when included in a fertilizer composition. One or more anaerobic digestion digestate compositions may be incorporated into the fertilizer compositions to dilute the sodium concentration to an acceptable level. As still another example, an anaerobic digestion digestate composition may provide additional carbon (C) in the fertilizer composition, which can be especially useful for soil microbe health and to the benefit of an agricultural crop. As discussed above, carbon tends to be consumed to a relatively high degree during the combustion of biomass to generate energy and form a bio-ash composition. According to the present disclosure, one or more anaerobic digestion digestate compositions can be combined with a bio-ash composition to form a fertilizer composition, and used as a supplemental source of carbon for soil microbes depending on the bioavailability of carbon in a given anaerobic digestion digestate composition.

[0052] In some embodiments, an anaerobic digestion digestate composition may be selected for providing desirable binding properties in a fertilizer composition such as discrete units so that the discrete units do not degrade to an undue degree during one or more of processing, storage, transportation, or application to soil, while at the same time degrading in a desirable manner after being applied to soil. Providing binding properties to a bio-ash composition can be advantageous. For example, a bio-ash composition can be relatively light and fluffy, which can make it difficult to apply to soil so that it remains in place without blowing away due to wind. In some embodiments, an anaerobic digestion digestate composition can make a fertilizer composition formed from a bio-ash composition and the anaerobic digestion digestate composition relatively denser so that the fertilizer composition does not blow around to an undue degree after being applied to soil.

[0053] The pH of an anaerobic digestion digestate composition can affect the bioavailability of one or more nutrients in a fertilizer composition formed therefrom. The pH of an anaerobic digestion digestate composition can vary (e.g., depending on concentration of an anaerobic digestion digestate composition). In some embodiments, an anaerobic digestion digestate composition can have a pH of 7.5 or less, 7 or less, 6.5 or less, 6 or less, 5.5 or less, 5 or less, or even 4.5 or less. The pH of an anaerobic digestion digestate composition may or may not be adjusted when forming a fertilizer composition. For example, mixing a highly acidic composition and a highly basic composition can be an exothermic process, which may be undesirable. In some embodiments, if an acidic anaerobic digestion digestate composition is to be combined with a component that has a relatively high pH (e.g., a bio-ash composition having a pH of 12 or greater), the pH of the acidic anaerobic digestion digestate composition may be increased to reduce the difference in pH prior to combining the anaerobic digestion digestate composition with the component that has a relatively high pH.

[0054] For illustration purposes, Table 1 includes compositional data for two anaerobic digestion digestate composition: AD effluent and AD mineral syrup. AD effluent was concentrated by removing water to form the AD mineral syrup.

[0055] A bio-ash composition can be mixed with at least one stillage composition and/or at least one anaerobic digestion digestate composition to form a fertilizer composition at a weight ratio based on a variety of factors such as those discussed above when selecting a stillage composition and/or an anaerobic digestion digestate composition. For example, the weight ratio can depend on the composition of the bio-ash composition, the stillage composition, the anaerobic digestion digestate composition, and/or the target composition of the fertilizer composition. In some embodiments a bio-ash composition is combined with a stillage composition in a weight ratio from 0: 100% to 100:0%, from 20:80% to 80:20%, from 40:60% to 60:40%, or even 50:50%. In some embodiments a bio-ash composition is combined with an anaerobic digestion digestate composition in a weight ratio from 0: 100% to 100:0%, from 20:80% to 80:20%, from 40:60% to 60:40%, or even 50:50%. In some embodiments a stillage composition is combined with an anaerobic digestion digestate composition in a weight ratio from 0: 100% to 100:0%, from 20:80% to 80:20%, from 40:60% to 60:40%, or even 50:50%.

[0056] In some embodiments, a stillage composition and/or an anaerobic digestion digestate composition are not filtered prior to forming a fertilizer composition. For example, a stillage composition and/or an anaerobic digestion digestate composition can include suspended solids, if desired. In some embodiments, an anaerobic digestion digestate composition may be allowed to settle in a settling tank to separate and reuse sludge in an anaerobic digestion process.

[0057] One or more of a bio-ash composition, a stillage composition, and an anaerobic digestion digestate composition can be formed into a fertilizer composition in a solid form and/or liquid form.

[0058] In some embodiments, a fertilizer composition can be formed into discrete units, which are solid forms of material formed by a variety of equipment. The discrete units are repeating units of a general shape and/or size that can be referred to as particles, granules, pellets, agglomerates, prills, and the like.

[0059] Non-limiting examples of equipment that can be used form a fertilizer composition into discrete units include an agglomerator, a pan granulator, a pelletizer, a prilling machine, and the like.

[0060] Forming discrete units can depend on one or more factors such as the equipment used to form the discrete units, process conditions used to form discrete units, composition of the fertilizer composition, including the moisture content of a fertilizer composition, and the like. [0061] Equipment and related process conditions that can influence forming discrete units include pressure and/or temperature. In some embodiments, a pellet mill can form pellets at a die pressure of up to 200 bar, e.g., from 10 to 100 bar. In some embodiments, a pellet mill can form pellets while exposing a fertilizer composition to a temperature of up to 200°C. [0062] Aspects of a fertilizer composition that can influence forming discrete units include one or more chemical constituents present in a fertilizer composition and/or one or more physical properties of one or more chemical constituents. The same aspects of the components used to make the fertilizer composition can influence forming discrete unit, and can be used when selecting one or more components to make a fertilizer composition. For example, as mentioned above and below, the average particle size of a bio-ash composition can influence forming discrete units. As another example, the content of protein, fat, fiber, starch, lignin, moisture, total solids, suspended solids, and/or dissolved solids in a stillage composition can influence forming discrete units. In some embodiments, a dry-grind com stillage composition that is used to make a fertilizer composition includes one or more of the following constituents shown in Table 2 in an amount in the stated range.

[0063] Likewise, the content of an anaerobic digestion digestate composition can influence forming discrete units.

[0064] As another example, one or more additional components, e.g., commercially available binders, (discussed below) can influence forming discrete units.

[0065] As mentioned, the moisture content of a fertilizer composition can influence forming discrete units. For example, if the moisture content is too high the viscosity of the fertilizer composition may be too low for the fertilizer composition to hold its shape to form discrete units. If the if moisture content is too low the viscosity of the fertilizer composition may be too high to be processed in the equipment. Also, the moisture content of a fertilizer composition is influenced by one or more components used to make the fertilizer composition such as a bio-ash composition, a stillage composition, an anaerobic digestion digestate composition, additional components (e.g., commercially available binders), and the like. In some embodiments, a fertilizer composition fed to equipment to form discrete units has a moisture content of at least 15% by weight of the total fertilizer composition, at least 20% by weight of the total fertilizer composition, or even at least 30% by weight of the total fertilizer composition. In some embodiments, a fertilizer composition fed to equipment to form discrete units has a moisture content from 15% to 60% by weight of the total fertilizer composition, from 20% to 0% by weight of the total fertilizer composition, or even from 20% to 40% by weight of the total fertilizer composition.

[0066] In some embodiments, a fertilizer composition is in the form of pellets. A pellet mill (pelletizer) can be used to form pellets. A pellet mill uses pressure and a die to form pellets as discrete units. For example, FIG. 6 shows pellets made according to Example 3 using a pellet mill. Optionally, the fertilizer composition can be exposed to steam in the pellet mill to condition the fertilizer composition to facilitate forming pellets. While not being bound by theory, it is believed that the relatively small particle size of the bio-ash composition can facilitate forming pellets using pellet mill dies having relatively small length-to-diameter ratios. In some embodiments, a pellet mill die can have a length-to-diameter (L/D) ratio of 15 or less, 10 or less, or even 5 or less.

[0067] FIG. 2 shows an example of a pan granulator (also known as a disc pelletizer) that can be used to form pellets. A pan granulator is a type of agitation agglomeration equipment that can form pellets via tumble growth, not pressure like a pellet mill. Referring to FIG. 2, a pan 202 is tiltably and rotatably mounted on base 201. Pan 202 has an inner side surface 203, an inner bottom surface 208 and a chamfer 204 between the inner side surface and the inner bottom surface. Frame 205 is supported above pan 202. An arm 206 (scraper or plow) is a vane-type component that can control the material layer as it tumbles over the bottom surface of pan 202. As shown, arm 206 is adjustable by being movable about pin 210. Motor (not shown) can cause pan 202 to rotate so that cause material to form pellets via tumble growth as pan 202 rotates. For illustration purposes, bio-ash composition and a binder such as a stillage composition and/or an anaerobic digestion digestate composition can be fed onto the pan 202 as it rotates, thereby causing the materal to tumble and grow to form pellets by agglomeration, which combines and binds smaller solid particles (fines) together using liquid binder. The arm 206 helps to remove buildup on the ban bottom and directs the pellets into separate streams as they grow in size. Eventually, the pellets grow to a size that causes them to exit over the side of the pan for collection. Pellet size can be controlled by adjusting the arm spacing from the inner bottom surface, the pan slope angle, rotation speed, time, moisture, temperature and feed rate of material onto the pan. Pelleting could also form coated seeds, if desired, as discrete units (pellets) having a noticeable change the shape, size, and/or weight of the coated seed as compared to the uncoated seed.

[0068] In some embodiments, pellets can have an average diameter of at least 1 mm, at least 2 mm, at least 5 mm, or even at least 10 mm. In some embodiments, pellets can have an average diameter from 1 to 10 mm, from 2 to 8 mm, or even from 3 to 7 mm. Depending on the average particle size of the bio-ash composition, the bio-ash composition may be reduced in particle size prior to forming pellets.

[0069] In some embodiments, a fertilizer composition can be formed into prills via a prilling machine and process. Prills are solid particles that have a generally spherical shape and an average diameter from about 0.5 to 4 mm. Prills can be formed by a process that includes forming a melt in one or more jets in a prilling machine. As the melt is forced through a jet it forms small discrete droplets that fall through a prilling tower where the droplets solidify into prills and are collected at the bottom of the prilling tower. A cooling gas can be introduced into a prilling tower in a countercurrent or co-current flow to help cool the droplets and form prills.

[0070] An agglomerator (also known as an agglomeration drum or rotary drum) can also be used to form pellets via tumble growth agglomeration. Like a pan granulator, an agglomerator tumbles solid particle “fines” in the present of a liquid binder to form pellets. [0071] A bio-ash composition can be mixed with one or more other components using a variety of mixers (mixing equipment). Non-limiting examples of mixers include a pin mixer, a feed mixer, a concrete mixer, and the like. In some embodiments, a pin mixer can be used to mix a bio-ash composition with one or more other components, e.g., prior to forming discrete units as described above. For example, a pin mixer may be used to mix a bio-ash composition with a stillage composition and/or an anaerobic digestion digestate composition prior to being fed to a pan granulator, a prill machine, a pellet mill, or an agglomerator. A pin mixer uses high-speed spinning action and a shaft with affixed rods (pins) to mix materials. Bio-ash composition is a powdery material that can aerosolize in air. To help mix a bio-ash composition with one or more liquid components, e.g., a stillage composition, the bio-ash composition can be slowly and gently combined with the one or more liquid components. Also, the bio-ash composition can be combined with the one or more liquid components in a vessel having a relatively small headspace to help the bio-ash composition combine with the one or more liquid components in a manner that avoid aerosolization of the bio-ash composition to an undue degree. In some embodiments, a mixer can both mix a bio- ash composition with other components to form a mixture and perform granulation of the mixture.

[0072] Generally, a pH around neutral is ideal for plant growth and nutrient bioavailability. The pH of the soil may or may not change after applying a fertilizer composition to the soil. For example, depending on the initial soil pH and application rate of the fertilizer composition, addition of the fertilizer composition may or may not change the pH of the soil. If desired, as discussed below, one or more of gypsum, sulfur, lime or other amendments can be applied to the soil to adjust the pH of the soil. The form of the fertilizer composition can influence whether, how fast, and/or to what degree the pH of the soil changes after applying the fertilizer composition to soil. For example, in some embodiments, a liquid fertilizer composition can change the pH of the soil relatively fast as compared to a solid fertilizer because, e.g., it may take additional time for a solid fertilizer to solubilize and change the pH of the soil. In at least one greenhouse study, an increase in pH was not detected after adding a bio-ash composition to soil. While not being bound by theory, it is believed that from the perspective of applying a fertilizer composition to soil the fertilizer composition is present in relatively very low amounts as compared to the soil it is applied to such that the pH of a fertilizer compositions tends to not result in a detectable change in soil pH. As discussed above, combining one or more components such as a stillage composition and/or an anaerobic digestion digestate composition can reduce the pH of the resulting fertilizer composition.

[0073] In some embodiments, the moisture content of solid fertilizers can be adjusted. For example, if desired, discrete units such as pellets or agglomerates can be dried to reduce the moisture content of the discrete units so that the pellets or agglomerates do not stick to each other in a manner that impacts handling and/or application to an undue degree. Non-limiting examples of equipment that can be used to dry discrete units include a drum dryer, a fluidized bed dryer, and combinations thereof. On the other hand, in some embodiments, pellets or agglomerates may be too dry, thereby causing them to crumble to an undue degree, which can be undesirable for handling and/or application. In some embodiments, one or more flow agents can be used when making discrete units so that the discrete units do not stick and clump together to an undue degree. An example of such a flow agent is calcium carbonate. [0074] In some embodiments, discrete units of fertilizer composition can have a moisture content of 20% or less, 15% or less, or even 10% or less by total weight of the discrete units. For example, discrete units of fertilizer composition can have moisture content in a range from 10-15% by total weight of the discrete units. [0075] Optionally, one or more additional components can be included in a fertilizer composition. In this sense, the “additional components” refer to components that are in addition to the at least one bio-ash composition, the at least one stillage composition, and/or the at least one anaerobic digestion digestate composition that may already be present in the fertilizer composition. Non-limiting examples of such additional components include one or more synthetic fertilizers, one or more soil amendments, one or more dedusting agents, one or more binders, one or more types of soil microbes, and the like. Such additional components may be commercially available. Non-limiting examples of such one or more additional components include molasses, one or more starches, manure, compost, lignosulfonate, carboxymethylcellulose, polyvinyl alcohol, monoammonium phosphate (MAP), diammonium phosphate (DAP), sodium silicate, lime, gypsum, dolomite, potash, out-of-spec feedstock, feedstock screenings, and combinations thereof. “Out-of-spec feedstock” refers to grain feedstock intended for a bioprocessing facility such as a dry -grind, corn ethanol facility, but does not meet specification. “Feedstock screenings” refers to organic fines, dirt, silt, and ash may be screened from the feedstocks such as grain feedstocks intended for a bioprocessing facility such as a dry-grind, corn ethanol facility. In some embodiments, a fertilizer composition mixed with an out-of-spec feedstock and/or feedstock screenings could be used as a compost product.

[0076] In some embodiments, one or more additional components may be present in an amount from 0.1 to 75 percent, from 0.5 to 50 percent, from 1 to 30 percent, from 1 to 20 percent, from 1 to 15 percent, from 1 to 10 percent, from 1 to 5 percent, or even from 1 to 3 percent by total weight of the fertilizer composition.

[0077] In some embodiments, as shown in FIG. 1, a fertilizer composition production system 120 is co-located in physical proximity to (“on-site”) a bioprocessing facility 105, which includes a thermal energy generating system 110. Co-locating a fertilizer composition production system 120 with bioprocessing facility 105 permits the fertilizer composition production system 120 and the bioprocessing facility 105 to be integrated with each so that one or more process streams can be readily shared among the fertilizer composition production system 120 and the bioprocessing facility 105. For example, materials produced in bioprocessing facility 105 (e.g., at least one stillage composition and/or at least one anaerobic digestion digestate composition) and thermal energy generating system 110 (e.g., bio-ash composition) can be readily transported to (e.g., via piping) and shared with the fertilizer composition production system 120. [0078] In more detail, as shown in the Figure 5, a facility 100 includes bioprocessing facility 105, which is configured to generate at least one stillage composition 107 and/or at least one anaerobic digestion digestate composition 109. Facility 100 also includes thermal energy generating system 110, which is configured to generate thermal energy 111 for the bioprocessing facility 105 and produce a bio-ash composition 113 via a combustion process of biomass at bioprocessing facility 105. Using the bio-ash composition in a fertilizer composition can help utilize the biomass from which it was derived in a circular manner by applying it to a field to grow more biomass. The bioprocessing facility 105 is configured to use at least a portion of the thermal energy 111 in one or more systems (not shown) in the bioprocessing facility 105. Non-limiting examples of thermal energy generating system 110 include a steam boiler system, a power generation system, and combinations thereof.

[0079] Facility 100 also includes fertilizer composition production system 120 that is colocated with the bioprocessing facility 105. The fertilizer composition production system 120 is in fluid communication with the bioprocessing facility 105 to receive at least one stillage composition 107 and/or at least one anaerobic digestion digestate composition 109. The fertilizer composition production system 120 is also in fluid communication with the thermal energy generating system 110 to receive bio-ash composition 113. The fertilizer composition production system 120 is configured to mix bio-ash composition 113 with stillage composition 107 and/or anaerobic digestion digestate composition 109 to form the fertilizer composition 121.

[0080] A fertilizer composition can have a variety of properties depending on the selection of type and amount of bio-ash composition and stillage composition and/or anaerobic digestion digestate composition, as discussed above. For example, a fertilizer composition can have a variety of nutrient profiles. For example, organic material can contribute carbon to a fertilizer composition. Depending on the bioavailability of the carbon in the organic material, organic material can modify the soil structure as it decomposes, allowing it to absorb and retain water and nutrients more efficiently. Soil-borne insects, worms, fungi, and other organisms may decompose the organic material, but obtain energy from available nitrogen to do so. In view of this, the fertilizer composition may be formulated to include sufficient nitrogen when undecomposed (not composted) organic material is present in a fertilizer composition. In some embodiments, a fertilizer composition can have a carbon (C): nitrogen (N) ratio in a range from 2: 12 to 1 : 1, from 3 : 10 to 1 : 1, from 4:9 to 1 : 1, or even from 1 :2 to 5:8 parts by weight. In some embodiments, if the relative amount of carbon is too high, then as the carbon containing material breaks down the nitrogen can be consumed in the process, thereby making less nitrogen available for the crop (e.g., corn) that is intended to receive the fertilizer nutrients. In some embodiments, a fertilizer composition has a total nitrogen content of 0.1% or greater by total weight of the fertilizer composition. In some embodiments, a fertilizer composition has a phosphate (P2O5) content of 0.5% or greater by total weight of the fertilizer composition. In some embodiments, a fertilizer composition has a potassium oxide (K2O) equivalent content of 3% or greater by total weight of the fertilizer composition. In some embodiments, a fertilizer composition has a total carbon content of greater than 0.5% by total weight of the fertilizer composition.

[0081] A fertilizer composition according to the present disclosure can be applied to a field in any desired manner, depending on whether it is in particle or liquid form, to grow an agricultural crop. In some embodiments, a fertilizer composition can be applied to the surface of soil and/or plant foliage, e.g., via one or more of dropping, dripping, spreading, spraying, combinations of these and the like. In some embodiments, a fertilizer composition can be incorporated into soil, e.g., via in-furrow.

[0082] Example 1

[0083] FIG. 4 is a graph that shows the results of an experiment that was performed to evaluate how a fertilizer composition that includes a bio-ash composition compared to a synthetic fertilizer when growing oat plants with a single (IX) recommended dose of fertilizer. The control included no added fertilizer. The “fertilizer” sample was ground commercial pellets that included urea, potash, and di-ammonium phosphate. The “bale ash” sample was derived from burning unbaled com stover outside. The “ash” was fly ash in powder form derived from burning corn stover in a solid-fuel boiler. The “10% ash, 90% DFS” sample was a blend in paste form of 10% by weight fly ash derived from burning corn stover in a solid-fuel boiler and 90% by weight of defatted syrup (DFS) derived from an ethanol plant. The “50% ash, 50% DFS” sample was a blend in paste form of 50% by weight fly ash derived from burning corn stover in a solid-fuel boiler and 50% by weight of defatted syrup (DFS) derived from an ethanol plant. As can be seen, the fertilizer samples made from ash were comparable to the synthetic fertilizer.

[0084] Example 2

[0085] This example demonstrates that pellets can be formed using a blend of fly ash and syrup.

[0086] The fly ash was formed by burning corn stover in a solid-fuel boiler at a dry-grind, corn ethanol facility. The fly ash included 99.5% total solids by weight, and 0.5% moisture by weight. The syrup was obtained from a different dry -grind, corn ethanol facility. The syrup included 76.6% moisture by weight, and 23.4% total solids by weight.

[0087] A blend was formed by combining 50% syrup by weight and 50% fly ash by weight. The blend had about -38.6—% moisture by weight.

[0088] The blend fed into a single pellet hydraulic press and pressure was applied using the hydraulic press so that a pellet formed at the open nozzle end of the hydraulic press. The pellets are shown in FIG. 5.

[0089] Example 3

[0090] This example compares two blends of bale ash and defatted syrup used in a pellet mill.

[0091] The bale ash was formed by burning corn stover. Th bale ash included 97.7% total solids by weight, and 2.3% moisture by weight. The defatted syrup was obtained from a drygrind, com ethanol facility. The defatted syrup included 62.7% moisture by weight, and 37.3% total solids by weight.

[0092] Blend A had about 10% by weight moisture, and was formed by combining about 125grams of defatted syrup and about 875 grams of the bale ash.

[0093] Blend B had about 20% by weight moisture, and was formed by combining 300 grams of defatted syrup and 700 grams of bale ash.

[0094] Each blend was formed by hand mixing bale ash and defatted syrup together in a bucket so that moisture was distributed uniformly in the blend.

[0095] Each blend was fed to the pellet mill and pressed into a die to make the ash pellets. The pellet mill is commercially available from California Pellet Mill Co. (CPM) under the tradename CL5 pellet mill, and includes a conditioner for steam or liquid. The pellet mill includes a hopper that each blend was fed into. A die is in contact with a single roller, and as the die rotates the roller turns. Material carried by rotation of the die is compressed between the die and the roller. As compressed material is forced through the die and cut by a knife at the desired length to form pellets. It was observed that some of the bale ash passed through the pellet as residual bale as without being formed into pellets. The residual bale ash may be recycled to the pellet mill via conveyor/elevator methods. It is noted that the bale ash particles may be crushed into even smaller particle sizes as they are exposed to compression in the pellet mill. Because the residual bale ash can be an even smaller particle size as compared to the bale ash fed to the pellet mill, aerosolization of the residual bale ash may be an issue. In some embodiments, the residual bale ash could be recycled via forced air instead of typical conveyor/elevator handling techniques. [0096] Blend A did not form any pellets. The blend did not pack the die as the blend was fed into the die to make a pellet, but instead exited the die as a mixture similar to the original feed material instead of a pellet. It is noted that 10% moisture may work with other blends of a different composition (e.g., by including an additional binder and/or a different stillage composition in addition to or instead of defatted syrup). It is also noted that Blend A may form a pellet under one or more different conditions. For example, if how water or steam was incorporated into Blend A it may form pellets. As another example, the L/D ratio of the pellet mill may be adjusted in a manner that would permit Blend A to form pellets.

[0097] Blend B formed pellets well as shown in FIG. 6. The pellets were air dried to form very hard pellets, which were stable and held together quite well. The final pellets were around 0.25 inch in diameter and at least 0.5 inches in length with an approximate moisture content of 9-12% by weight.

[0098] Pellets were made from Blend B using a die having a length-to-diameter (L/D) ratio from about 10 to below 7. Based on this data, it is believed that pellets formed from blend B using a pellet mill die having an L/D of 5. While not being bound by theory, it is believed that the fine particle size of the bale ash permitted the blend B to be compressed using a pellet mill die having an L/D as low as 5.

[0099] As demonstrated by this example, defatted syrup can be combined with bale ash in a weight ratio to provide good pellet forming characteristics, while at the same functioning as binding agent for pellets.

Claims

WHAT IS CLAIMED IS:

1. A method of making a fertilizer composition, wherein the method comprises mixing at least one bio-ash composition and at least one composition chosen from at least one stillage composition, at least one anaerobic digestion digestate composition, and combinations thereof, to form the fertilizer composition.

2. The method of claim 1, wherein the at least one stillage composition is chosen from whole stillage, thin stillage, concentrated thin stillage (syrup), defatted syrup, defatted emulsion, clarified thin stillage, distiller’s oil, distiller’s grain, distiller’s yeast, and combinations thereof.

3. The method of any preceding claim, wherein the at least one anaerobic digestion digestate composition is chosen from anaerobic digestion liquid effluent, anaerobic digestion solid effluent, and combinations thereof.

4. The method of any preceding claim, wherein the at least one composition has a total nitrogen content of 0.1% or greater by total weight of the at least one composition.

5. The method of any preceding claim, wherein the at least one composition has a phosphate (P2O5) content of 0.1% or greater by total weight of the at least one composition.

6. The method of any preceding claim, wherein the at least one composition has a potassium oxide (K2O) equivalent content of 0.1% or greater by total weight of the at least one composition.

7. The method of any preceding claim, wherein the at least one composition has a total carbon content of greater than 5% by total weight of the at least one composition.

8. The method of any preceding claim, wherein the bio-ash composition has a total nitrogen content of 0.1% or greater by total weight of the bio-ash composition.

9. The method of any preceding claim, wherein the bio-ash composition has a phosphate (P2O5) content of 0.5% or greater by total weight of the bio-ash composition.

10. The method of any preceding claim, wherein the bio-ash composition has a potassium oxide (K2O) equivalent content of 1% or greater by total weight of the bio-ash composition.

11. The method of any preceding claim, wherein the bio-ash composition has a total carbon content of 5% or less by total weight of the bio-ash composition.

12. The method of any preceding claim, wherein the at least one bio-ash composition is chosen from bio-ash fly ash, bio-ash bottoms ash, and combinations thereof.

13. The method of any preceding claim, wherein the at least one bio-ash composition is derived from combustion of one or more plant-based feedstocks.

14. The method of any preceding claim, wherein the fertilizer composition has a carbon (C): nitrogen (N) ratio in a range from 2: 12 (e.g., from 3: 10, from 4:9, or even 5:8) to 1 : 1.

15. The method of any preceding claim, further comprising forming the fertilizer composition into discrete units.

16. The method of claim 15, wherein forming the fertilizer composition into discrete units comprises drying the discrete units to have moisture content of 20% or less by total weight of the discrete units.

17. The method of claim 15, wherein the discrete units are chosen from granules, pellets, prills and combinations thereof.

18. The method of any preceding claim, wherein, prior to the mixing, one or more bio-ash compositions are exposed to a particle-size reduction process to reduce an average particle size of the one or more bio-ash compositions.

19. The method of any preceding claim, wherein the at least one bio-ash composition comprises two or more bio-ash compositions, and wherein at least one bio-ash composition is different from another bio-ash composition based on average particle size, chemical composition, and combinations thereof.

20. A facility comprising: a bioprocessing facility configured to generate at least one composition chosen from at least one stillage composition, at least one anaerobic digestion digestate composition, and combinations thereof; at least one thermal energy generating system configured to generate thermal energy for the bioprocessing facility and produce a bio-ash composition via a combustion process, wherein the bioprocessing facility is configured to use at least a portion of the thermal energy in one or more systems in the bioprocessing facility; and a fertilizer composition production system that is co-located with the bioprocessing facility, wherein the fertilizer composition production system is in fluid communication with the bioprocessing facility to receive at least a portion of the at least one composition, wherein the fertilizer composition production system is in fluid communication with the at least one thermal energy generating system to receive at least a portion of the bio-ash composition, and wherein the fertilizer composition production system is configured to mix the at least a portion of the bio-ash composition and the at least a portion of the at least one composition to form the fertilizer composition.

21. The facility of claim 20, wherein the at least one thermal energy generating system is chosen from at least one steam boiler system, at least one dryer system, at least one power generation system, at least one regenerative thermal oxidizer, and combinations thereof.

22. A fertilizer composition comprising discrete units, wherein each discrete unit comprises a mixture of at least one bio-ash composition and at least one composition chosen from at least one stillage composition, at least one anaerobic digestion digestate composition, and combinations thereof.

23. A fertilizer composition comprising a mixture of at least one bio-ash composition and at least one composition chosen from at least one stillage composition, at least one anaerobic digestion digestate composition, and combinations thereof, wherein the fertilizer composition has a carbon (C): nitrogen (N) ratio in a range from 2: 12 (e.g., from 3: 10, from 4:9, or even 5:8) to 1 : 1.

24. The fertilizer composition of any preceding claim, wherein the fertilizer composition has a total nitrogen content of 0.1% or greater by total weight of the fertilizer composition.

25. The fertilizer composition of any preceding claim, wherein the fertilizer composition has a phosphate (P2O5) content of 0.5% or greater by total weight of the fertilizer composition.

26. The fertilizer composition of any preceding claim, wherein the fertilizer composition has a a potassium oxide (K2O) equivalent content of 3% or greater by total weight of the fertilizer composition.

27. The fertilizer composition of any preceding claim, wherein the fertilizer composition has a total carbon content of greater than 0.5% by total weight of the fertilizer composition.

28. A method of using a fertilizer composition according to any preceding claim, wherein the method comprises applying the fertilizer composition to soil to grow an agricultural crop (e.g., corn).

29. A method of making a fertilizer composition, wherein the method comprises forming a fertilizer composition into discrete units, wherein the fertilizer composition comprises at least one composition chosen from at least one bio-ash composition, at least one stillage composition, at least one anaerobic digestion digestate composition, and combinations thereof.

30. The method of claim 29, wherein the fertilizer composition further comprises one or more additional components chosen from one or more synthetic fertilizers, one or more soil amendments, one or more binders, one or more dedusting agents, one or more types of soil microbes, and combinations thereof.

31. The method of claim 31, wherein the fertilizer composition comprises at least one bio-ash composition and at least one additional component, wherein the at least one additional component is different than the at least one bio-ash composition, the at least one stillage composition, and the at least one anaerobic digestion digestate composition, and wherein the at least one additional component is chosen from molasses, one or more starches, manure, compost, lignosulfonate, carboxymethylcellulose, polyvinyl alcohol, monoammonium phosphate (MAP), diammonium phosphate (DAP), sodium silicate, lime, gypsum, dolomite, potash, and combinations thereof.

32. A fertilizer composition comprising discrete units, wherein each discrete unit comprises a composition chosen from at least one bio-ash composition, at least one stillage composition, at least one anaerobic digestion digestate composition, and combinations thereof.