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<p>The advancement of controlled-release fertilizers (CRFs) offers a transformative approach in enhancing nitrogen use efficiency in modern agriculture. This study introduces a novel method for synthesizing CRF by encapsulating uncoated urea (UCU) with biochar derived from mustard straw (MS) and employing bio-adhesive binders, including potato starch (PS), corn starch (CS), bentonite clay (BC), and <i>Calotropis gigantea</i> (CG). MS was pyrolyzed in N₂ or CO₂ environments to produce nitrogen-rich (MSB<sub>N</sub>) or carbon-rich (MSB<sub>C</sub>) biochar, which were evaluated as coating materials for biochar-coated urea (BCU) formulations. Coating was performed using pan coater and fluidized bed granulation (FBG) techniques with varied biochar–binder ratios. While prior research has explored various facets of CRF, however studies on specific need and optimal quantity of binders are still not much available in the literature. Gray correlation analysis (GCA) identified the optimal formulations, highlighting CG as the most effective binder across all techniques due to its superior ability to enhance coating uniformity and mechanical integrity. The findings revealed that increasing binder concentration from 2 to 8% significantly reduces dust generation while deteriorating structural stability and crushing strength. MSB<sub>C</sub>, with a greater surface area (9.584 m<sup>2</sup>&#xa0;g⁻<sup>1</sup>), higher porosity, and elevated electrical conductivity (7.411 S m⁻<sup>1</sup>), emerged as the most suitable biochar used as a coating material in CRF. Among the fabricated formulations of varied BCU, F-BCU-CCG, comprising 50% UCU, 40% MSB<sub>C</sub>, 5% CG, and 5% water in FBG, demonstrated exceptional performance, achieving a crushing strength of 1343&#xa0;g&#xa0;mm⁻<sup>2</sup>, granulation efficiency of 96.3%, coating percentage of 9.56%, and superior structural stability. This study addresses critical gaps in the literature regarding biochar–binder optimization using GCA and establishes CG and MSB<sub>C</sub> as key components for advancing CRF technology, paving the way for sustainable agricultural practices.</p> Graphical Abstract <p></p>

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Preparation, characterization, and analytical studies of mustard straw–derived biochar-coated urea utilizing different binders

  • 期刊论文

  • 发表日期：

    2025年2月7日

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  • Meenu,
  • Manish Vashishtha,
  • Susarla Venkata Ananta Rama Sastry

摘要

The advancement of controlled-release fertilizers (CRFs) offers a transformative approach in enhancing nitrogen use efficiency in modern agriculture. This study introduces a novel method for synthesizing CRF by encapsulating uncoated urea (UCU) with biochar derived from mustard straw (MS) and employing bio-adhesive binders, including potato starch (PS), corn starch (CS), bentonite clay (BC), and Calotropis gigantea (CG). MS was pyrolyzed in N₂ or CO₂ environments to produce nitrogen-rich (MSBN) or carbon-rich (MSBC) biochar, which were evaluated as coating materials for biochar-coated urea (BCU) formulations. Coating was performed using pan coater and fluidized bed granulation (FBG) techniques with varied biochar–binder ratios. While prior research has explored various facets of CRF, however studies on specific need and optimal quantity of binders are still not much available in the literature. Gray correlation analysis (GCA) identified the optimal formulations, highlighting CG as the most effective binder across all techniques due to its superior ability to enhance coating uniformity and mechanical integrity. The findings revealed that increasing binder concentration from 2 to 8% significantly reduces dust generation while deteriorating structural stability and crushing strength. MSBC, with a greater surface area (9.584 m2 g⁻1), higher porosity, and elevated electrical conductivity (7.411 S m⁻1), emerged as the most suitable biochar used as a coating material in CRF. Among the fabricated formulations of varied BCU, F-BCU-CCG, comprising 50% UCU, 40% MSBC, 5% CG, and 5% water in FBG, demonstrated exceptional performance, achieving a crushing strength of 1343 g mm⁻2, granulation efficiency of 96.3%, coating percentage of 9.56%, and superior structural stability. This study addresses critical gaps in the literature regarding biochar–binder optimization using GCA and establishes CG and MSBC as key components for advancing CRF technology, paving the way for sustainable agricultural practices.

Graphical Abstract