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Handling and Using Fertilizers Australian

Soil
Fertility
Manual

It is important for users of fertilizer to The physical quality of a fertilizer is an


understand the basic physical properties of important factor affecting the ease, speed and
fertilizers and how they can be adversely uniformity of application. Solid products
affected by storage conditions, transport and should be free flowing and free of aggregated
handling procedures. It is equally important to particles (lumps) caused by caking. If
be able to calculate fertilizer product application application is being made through a fertilizer
rates from recommendations for application of box or broadcast applicator, it is essential that
individual plant nutrients. the product is of a consistent particle size to
ensure an even application pattern.
This chapter provides a summary of the basic
physical properties of solid fertilizers, The majority of fertilizers used in large-scale
recommended storage, transport and handling agriculture and horticulture are applied in solid
practices, practical information on converting form through some type of application
recommended nutrient application rates to equipment. The most important physical
fertilizer product application rates, hints on problems that can be encountered in the
fertilizer applicator calibration, applying handling and use of these products are caking or
fertilizers through irrigation water, and setting (the formation of aggregated particles or
guidelines for safe handling of fertilizers. lumps), excessive moisture uptake, dustiness,
and segregation of particles.

Fertilizer Quality Physical properties are most important for their


influence on the handling and storage
Both its physical quality and its plant nutrient
characteristics of fertilizer products, but can

chapter 13
content will determine the suitability of a
also influence the agronomic performance
fertilizer for a particular use. The nutrient
of some.
content, its chemical form, and many factors
that affect the physical quality of fertilizers are
beyond the control of the user and others in the Particle size
distribution chain. However, inappropriate Particle size is defined as the particle diameter
storage and handling can lead to a deterioration range of the material. Particle size analysis is
in physical quality, and this in turn may affect typically measured by sieving, a process of
evenness, cost and convenience of application separating a mixture of particles according to
and losses which may impact on soil and their size fraction. Particle size affects
water quality. agronomic response; granulation and process
performance (during manufacture); and
blending, storage, handling, and application
Physical Quality and Properties of properties (1).
Solid Fertilizer Reducing particle size increases the total surface
Fertilizers are supplied in a variety of physical area of a material. The greater the surface area,
forms including solids, liquids and - in the case the greater reactivity of the particle. For
of anhydrous ammonia - as a compressed gas. products that have low solubility, such as
Solid products may be supplied as powders, phosphate rock and lime, grinding the material
crystals, prills, or granules. to a smaller particle size improves its dissolution
and reaction in the soil solution and its
The most suitable physical form for a fertilizer is
availability for uptake by plants. Elemental
normally determined by its chemical
sulfur (S) also requires a fine particle size to
characteristics, end-use, and application
maximise the surface area available for
method. For example, products that are very
Thiobacillus bacteria to convert it to the plant
low in solubility must be supplied in a finely
available sulfate form.
ground form to ensure rapid dissolution and
plant availability, whereas products for Fine powders, dusty fertilizers, and small
application through fertilizer boxes or crystals are particularly susceptible to caking or
air-seeders will normally be in granular or setting because their larger surface area results
prill form. in greater uptake of moisture and reaction with
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AUSTRALIAN SOIL FERTILITY MANUAL

adjacent particles. Dusty materials may pose a health a product, which in turn affects storage and handling
risk through irritation to eyes and soft tissues. Dusty properties. Hygroscopicity is defined as the moisture
and fine materials are susceptible to drift when absorption properties of a fertilizer under specified
broadcast applied. conditions of temperature and humidity(1). Most
fertilizers are hygroscopic to some extent because of
The particle size range is measured in microns (one their normally high water solubility. The hygroscopic
micron = one thousandth of a millimetre) for very fine properties of a fertilizer can be quantified and qualified
materials and in millimetres for granular and prilled by measuring the Critical Relative Humidity (CRH)
material. and its moisture absorption-penetration
In countries where fertilizer is applied by hand, an characteristics(1).
acceptable size range specification might be a product The more hygroscopic a fertilizer is, the more problems
which falls in the size range of 90% between 1 mm and one can expect during storage and handling.
4 mm in diameter. However, for products that are to be
applied mechanically or pneumatically, e.g., through The CRH for a range of commonly used fertilizer
air-seeders, in countries such as Australia, a typical products is shown in Table 13.1. The Critical Relative
specification is for a product that is in the size range of Humidity is defined as the relative humidity of the
96% between 2 mm and 4 mm diameter. atmosphere at which the material begins to absorb
moisture from the atmosphere and below which it will
Particle size is very important for fertilizer blends. A not absorb atmospheric moisture(1).
mis-match in size range, or the degree of uniformity
within a size range, between different blend Table 13.1 Critical Relative Humidity (CRH) of some
components will result in a product that is susceptible fertilizer products.
to segregation through vibration during transport, Product CRH (at 30C)
when stored in piles, or when propelled through the air Urea 70-75
by application machinery. The larger particles will tend Ammonium nitrate 55-60
to flow to the bottom of a pile while the smaller Ammonium sulfate 75-85
particles will be retained further up the slope. The Diammonium phosphate (DAP) 65-75
larger particles also travel further through the air when
Monoammonium phosphate (MAP) 70-75
propelled from a spreader.
Triple superphosphate (TSP) 75-85
Single superphosphate (*) 80-85
Granule hardness and integrity
Potassium chloride (Muriate of potash) 70-80
The mechanical strength of a granule or prill will
Potassium nitrate 80-85
largely determine its ability to withstand the
degradation that can occur in handling and storage. Potassium sulfate (Sulfate of potash) 75-80
Nitrophosphate (12-5.3-14-1.2Mg) 60-65
The crushing strength of a particle is important in *
Single superphosphate data supplied by Incitec Ltd
determining the storage properties of a product. For (Fertilizer Manual 1998)
example a granule which can be crushed between the
thumb and forefinger is classified as soft. If it can be The CRH normally decreases with increase in
crushed with the forefinger on a hard surface, it is temperature.
regarded as being of medium hardness. If it remains
intact when subjected to pressure by the forefinger Fertilizers vary considerably in their ability to tolerate
against a hard surface, it is classified as hard(1). absorbed moisture. The factors that most affect the
moisture absorption-penetration characteristics of a
Abrasion will generate fine particles and dust as a result fertilizer are its chemical composition, particle
of granules or prills rubbing against one another porosity, particle surface area, and degree of
during handling. Prilled materials are generally more crystallinity.
susceptible to abrasion than granular forms of the same
product. The transfer of fertilizers through augers is a It should be noted that a mixture of two fertilizers
common cause of product degradation through generally has a lower critical relative humidity than
abrasion. either of the constituents. However, in some cases it
will be very significantly depressed, e.g. urea and
Products will tend to break up when impacted against a ammonium nitrate are incompatible because a mixture
hard surface. This occurs during loading and discharge of these two materials has a critical relative humidity of
of ships, when bagged product is dropped, and when approximately 18 (at 30C).
product is propelled through application equipment.
Granular materials generally have greater impact Caking of fertilizers
resistance than prilled materials. Caking of fertilizers is caused by the formation of
contact points between the particles. A major cause of
Hygroscopicity caking is the formation of salt bridges (or crystal
Hygroscopicity is an important characteristic of solid bridges) between the particles at the contact point.
fertilizers because of its effect on the physical quality of These develop during storage as a result of continuing

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HANDLING AND USING FERTILIZERS

internal chemical reactions, dissolution/ Packaged fertilizer should be transported in such a


recrystallization processes, and/or thermal effects(1). way that no damage to packages occurs and no
spillage of product occurs;
Adhesive contacts are formed as a result of molecular
attraction between the surfaces in contact. This type of Packaged fertilizer should be protected from adverse
caking typically occurs from pressure exerted on the weather such as rainfall;
fertilizer when it is stacked in bags or piled in bulk,
usually referred to as bag or pile set. The material Fertilizer classified as a Dangerous Good must be
normally reverts to a free-flowing form with a minimal transported in accordance with the relevant
amount of handling(1). Transport Regulation and relevant provisions in the
Australian Dangerous Goods Code;
Surface diffusion of water-salt complexes forming
contact with adjacent particles also causes caking, and The relevant Transport Regulation limit on load size
this mechanism is greatly influenced by the porous must be observed;
structure of particles(1). After discharging fertilizer, the driver should ensure
Product related factors that influence caking include: that all fertilizer is removed from the vehicle.
the chemical composition and impurity content,
moisture content, the size and shape of particles, the Adverse events
mechanical strength and resistance to breakdown, the In the event of any spillage of fertilizer products, the
hygroscopicity, and temperature when placed in driver should take immediate steps to prevent any
storage. External factors of importance include: further loss or contamination of any waterways. The
warehouse storage temperature, atmospheric humidity, driver should minimise any hazard to other road users
the length of storage time, and the pressure from and should ensure that no residual product remains
stacking or being at the bottom of a pile. that may pose any immediate or future threat to the
environment.

Handling Fertilizers At the earliest opportunity, the relevant local


government authority should be advised of any spillage
A containment approach should be adopted for the
risks to waterways, ponds, lakes, or ground water.
handling and use of fertilizer. This means that during
the transport, storage, and any other handling
Loading and unloading bulk fertilizer
operations, operators should ensure that the fertilizer is
contained within the transport vehicle or storage site so Fertilizers should be moved with belt conveyors or
that possible adverse environmental effects from tubulators in preference to augers. Worn augers will
spillage are avoided. crack the granules, creating fines and dust. The dust
forms layers in field bins and silos, which will cause the
The loss of product during the handling, transport, or product to cake. It is these layers of dust and fines that
storage of fertilizer is a potential point source of attract moisture. Dust has a far greater surface area
pollution, which can be effectively managed if than granules and therefore absorbs atmospheric
appropriate actions are taken. moisture more quickly.

Recommended transport procedures Storage and handling of bulk


All fertilizer products should be delivered to users free Fertilizer should be kept dry and free from
of any extraneous matter. Loading and unloading contamination. One way of achieving this is to use a
procedures should be designed to minimise product storage area with a roof, concrete floor (which includes
degradation, e.g. segregation of fertilizer components, a damp proof course), and concrete walls of sufficient
uptake of moisture, physical changes to particle size, height to allow front end loaders to operate effectively
and contamination. when loading out of storage. The floor should be
designed to bear the weight of vehicles during loading
General requirements for the transport of fertilizers
and unloading.
are:
To keep the fertilizer in the same condition during
Bulk carriers should be such that no spillage of
storage, it is important to control any moisture changes
fertilizer can occur during transport;
in the fertilizer. Fertilizer to be stored for a period
Bulk carriers should be presented in a clean before use should be covered with impermeable
condition so that no contamination occurs. sheeting to prevent contact with moist air. The cover
Sheeting used to cover bulk product should be free should be arranged so that all air movement is
from contamination; eliminated. Canvas tarpaulins are not suitable because
they are permeable.
All bulk loads of fertilizer products should be
securely covered so as to prevent any dust nuisance Impermeable sheeting placed on top of the fertilizer in
during transportation and to prevent moisture the bin or silo will further protect the fertilizer from
uptake; atmospheric moisture. Care is necessary to make sure

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AUSTRALIAN SOIL FERTILITY MANUAL

that the sheeting does not get sucked into the fertilizer The greater the impact of any of these factors, the
when emptying the bin. shorter the safe storage life of the fertilizer.
The period which fertilizer can be stored without Storage conditions
covering depends on weather conditions (humidity) Ingress of moisture and humid storage conditions will
and the characteristics of the fertilizer (i.e. is the increase the likelihood of the product setting or
fertilizer hygroscopic). becoming sticky, regardless of fertilizer type.
Worn auger flights will damage (grind) all fertilizers,
Type of fertilizer
especially coated fertilizers, and should be avoided.
Fertilizers containing nitrogen (N) or potassium (K),
Silos used for storage of fertilizer must be designed to including mixtures of them, or either or both with
accommodate the physical properties of the fertilizer phosphorus (P) fertilizers are more likely to take up
being stored (refer AS 3773 Bulk Solids Containers moisture in humid conditions. Straight P fertilizers are
Safety Requirements and AS 3744 Loads on Bulk less affected by humid conditions.
Solids Containers).
Physical condition of fertilizer
All bulk nitrogen fertilizers, nitrogen/phosphorus Fertilizer granules that have been physically degraded
fertilizer mixtures, and compound fertilizers should be and/or contain fines will absorb moisture much more
stored in sheds and covered with impermeable sheeting quickly than non-degraded product. This will lead to a
to exclude moist air. Storage of these products in field higher likelihood of the product setting.
bins or silos is not generally recommended.
In general terms P fertilizer can be stored for longer
Different fertilizers have different flow and bulk density periods than N, K, N/P mixtures and N, P and K
properties. Where bulk fertilizer is stored in bins and is mixtures or compound fertilizers.
unloaded mechanically or by gravity, the bin should be
However, prolonged storage of any fertilizers requires
designed to handle the loads imposed and allow the
caution and must take into account the factors which
stored fertilizer to flow freely. Particular attention
impact storage life.
needs to be paid to ensuring that the valley angle of the
cone at the bottom of the silo and the angle of the
unloading chute are sufficiently steep. If in doubt on Disposal of Packaging and Containers
any aspect of bin design, seek specialist advice. General
Under no circumstances should any method of disposal
Packaged fertilizer of fertilizer packaging be undertaken where there is any
Any packaged (bagged) fertilizer should be stored in risk of adverse environmental effects.
impermeable bags or bags with impermeable liners. If
stored on open wood floors, plastic sheeting should be Containers
placed under the bags and wrapped around the whole While most fertilizer materials are handled in bulk,
stack. some products are provided in bags of varying sizes and
some as liquids. As a first option, recyclable packaging
All packaged fertilizer, including flexible intermediate
should be used if available. For all other situations,
bulk containers (FIBC or bulk bags) should be stored
users should ensure that packaging is disposed of in a
away from direct sunlight and rainfall. Fertilizer in
manner which minimises the risk of adverse effects on
bulk bags will compact if stored more than 2 high.
the health of people or the environment.
Bulk bags should have impermeable sheeting
underneath when stored on dirt or a concrete floor. Particular attention must be paid to preventing woven
polypropylene packaging from contaminating wool
Pallets stacked with 50 kg size, or less, bags of fertilizer
clips.
should not be stored more than 3 pallets high to avoid
compaction and splitting of bags. Disposal options may include:
Stocks of packaged fertilizer should be rotated so that Alternative use (users should ensure that the
the older fertilizer is used first. container is completely empty. For liquid
containers this may mean triple rinsing);
Storage times Recycling;
In general, the nutrient value of fertilizer is not
Sanitary landfills users should check with the local
diminished in any way during storage. However the
government authority to confirm that packaging
physical handling characteristics of fertilizers in storage
material for fertilizers can be disposed of in landfills
are likely to be adversely affected over time. The
in their region;
storage conditions, the type of fertilizer, and the
physical condition of the product will determine the Burning in some areas controlled incineration
period for which fertilizers can be satisfactorily stored. may be a disposal option.

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HANDLING AND USING FERTILIZERS

Nutrient Content and Quality chemical formula KCl and in a pure sample, the K
The nutrient content and the form in which that content is 52.4% and the chlorine (Cl) 47.6%.
nutrient is present largely determine the performance A pure sample of diammonium phosphate (DAP) with
of any fertilizer. The form in which the nutrient is the formula (NH4)2HPO4 would contain N 21.2%, P
present may affect its availability or its effect on the 23.5%, O 48.5%, and H 6.9%. However, because the
plant. Fertilizers may also contain impurities that need phosphate rock used in the manufacturing process
to be taken into account by users, e.g. heavy metals as contains a range of impurities such as iron and
discussed in Chapter 11. aluminum, and these form various salts in the
In Australia, labelling of fertilizers is required by production process, the analysis of DAP fertilizer will
legislation administered by State government always be lower than the pure form.
authorities. While there may be some difference in the
detail of regulations from State to State, there is a Form of ingredient
relatively uniform requirement for the statement of The label must state the form and concentration of the
nutrient content. Fertilizer products must have a label elements N, P, K, and S when present in the fertilizer, in
printed, stencilled, or securely affixed to the package. In the forms shown in Table 13.2.
the case of bulk fertilizer, a label or advice note
containing the label information must accompany The label must show maximum concentrations for
each load. cadmium (Cd), mercury (Hg), and lead (Pb), where
maximum concentrations of each metal are required to
The label or advice note will usually state or contain: be shown by regulation. For phosphorus fertilizers, the
the distinguishing name of the product; the quantity of cadmium content is also usually shown as a percentage
fertilizer within the package or bulk delivery; the name of the phosphorus content.
and full business address of the supplier; an analysis of
the ingredients of the fertilizer; and any applicable For products sold by weight, the concentration of each
warning statements that are prescribed under ingredient in a fertilizer must be expressed on the label
regulation. In some States a description of the nature of or advice note as the percentage weight in weight (w/w)
the product and a statement of the intended purpose of and as the percentage weight in volume (w/v) for all
the product is also required on the label or advice note. products sold by volume.
The concentration of each ingredient on the label or
Statement of nutrient content
advice note must be placed opposite to that ingredient
The major nutrients, nitrogen (N), phosphorus (P),
on the label or advice note.
potassium (K) and sulfur (S) must be shown on the
label or advice note in the following order: N, P, K, S
with all other ingredients listed in decreasing quantity. Lime, Dolomite and Liming Materials
It should be noted that it is only the nutrient content of The definitions of lime, dolomite, and liming materials
the product that appears on the label, and the other currently (1999) vary to some extent from State to
components of the product are not shown. Fertilizer State. The information required on the label or advice
products are typically mineral salts (e.g. potassium note (with bulk loads) also varies from State to State.
chloride, diammonium phosphate) or an organic
However, the key requirement is that the label contains
compound in the case of urea.
sufficient information for the user to assess the capacity
A common misconception among people not familiar of the product to increase soil pH in relation to its cost.
with fertilizer products is that all fertilizers include This capacity is a function of the type of liming
filler of some description. This is probably because only material and, in the case of limestone and dolomite, the
the nutrient content is given in the product fineness of the particle (refer Selecting a Liming
specification and label. For example urea is 46% N and Material Quality Aspects, Chapter 2). The reactivity
has the chemical formula CO(NH2)2. In a pure sample of limestone increases as its particle size decreases.
of urea the N content is 46.7% and the balance is made However, the cost of the product is increased as a result
up of carbon (C) 20.0%, oxygen (O) 26.6%, and of grinding, and very fine material is difficult to handle
hydrogen (H) 6.7%. Potassium chloride has the and apply.

Table 13.2 Forms of nutrient to be specified on label.


Nitrogen % Phosphorus % Potassium % Sulfur %
(N) as urea (P) as water soluble (K) as sulfate (S) as sulfate
(N) as ammonium (P) as citrate soluble (K) as chloride (S) as elemental sulfur
(N) as nitrate (P) as citrate insoluble (K) as nitrate
(N) as other (form to be (P) as other (form to (K) as other (form to (S) as other (form to
stated) be stated) be stated) be stated)
(N) total (P) total (K) total (S) total

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Some States require the label to show the neutralising lime having a particle size of not more than 75
value of the material and the degree of fineness e.g. the microns;
percentage passing through a 250 micron aperture
(b) the value obtained by multiplying 58% of the
must be stated.
neutralising value of the lime by the percentage
The neutralising value of a liming material is a mass of the lime having a particle size of more
measure of its chemical capacity to influence pH than 75 microns but not more than 150 microns;
relative to pure calcium carbonate (CaCO3). Refer
(c) the value obtained by multiplying 50% of the
Table 2.3 for a comparison of the neutralising value of
neutralising value of the lime by the percentage
various materials using CaCO3 as the benchmark value
mass of the lime having a particle size of more
of 100.
than 150 microns but not more than 250 microns;
The effective neutralising value is a measure of the
(d) the value obtained by multiplying 42% of the
products capacity to influence pH, which takes
neutralising value of the lime by the percentage
account of the reactivity of the material as determined
mass of the lime having a particle size of more
by its particle size as well as its chemical reactivity or
than 250 microns but not more than 500 microns;
neutralising value.
(e) the value obtained by multiplying 34% of the
In some States labels are required to show the grade of neutralising value of the lime by the percentage
the material according to its Effective Neutralising mass of the lime having a particle size of more
Value whereby, Grade 1 must be no less than 85% than 500 microns but not more than 1000
effective, Grade 2, no less than 65%, and Grade 3, no microns;
less than 50%. Under current Regulations in these
States, the Effective Neutralising Value is to be (f) the value obtained by multiplying 22% of the
calculated according to the following formula: neutralising value of the lime by the percentage
mass of the lime having a particle size of more
Effective Neutralising Value of the material is the sum than 1000 microns but not more than 2000
of the following values: microns;
(a) the value obtained by multiplying the neutralising (g) the value obtained by multiplying 12% of the
value of the lime by the proportion of lime having neutralising value of the lime by the percentage
a particle size of not more than 300 microns; mass of the lime having a particle size of more
(b) the value obtained by multiplying 60% of the than 2000 microns.
neutralising value of the lime by the proportion of While finer particle size improves the reactivity of lime,
lime having a particle size of more than 300 there are practical limitations to spreading ultrafine
microns but not more than 850 microns; product.
(c) the value obtained by multiplying 10% of the
neutralising value of the lime by the proportion of Gypsum
lime having a particle size of more than 850 The definition of gypsum also currently varies from
microns. State to State.
The above calculations assume a particle size of 300 Gypsum is defined by regulations in some States as
microns represents a threshold of 100% relative material containing the sulfate salt of calcium (Ca) in
effectiveness. However, field research by NSW either hydrated or anhydrous form where the amount
Agriculture, Agricultural Research Institute Wagga of that salt in the material is not less than 50%. In most
Wagga (Scott et al., Aust. J. Agric. Res., 43, 11751185 States, the label or advice note must state the grade of
and Conyers et al., Fertilizer Research, 44: 151161), has gypsum. In some States, the percentage of gypsum
shown that the threshold value should be set at a much capable of passing through at 2mm sieve must be
finer particle size. In fact, all recorded studies show that specified.
effectiveness increases with smaller particle size.
The generally agreed standards are for three grades of
Based on this research, a more sensitive method of natural or mined gypsum:
calculating the effectiveness of lime, which takes
account of the greater reactivity of particles below 300 Sulfur Minimum (%) Calcium Minimum (%)
micron size has been suggested. The sum of the Grade 1 15 19
following values can then be used to determine the Grade 2 12.5 15.5
effective neutralising value and compare different
Grade 3 10 12.5
materials.
(a) the value obtained by multiplying the neutralising Phosphogypsum (a by-product of phosphoric acid
value of the lime by the percentage mass of the production) must contain a minimum of 14% S and

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HANDLING AND USING FERTILIZERS

18.5% Ca in NSW, a minimum of 14% S and of products. When fertilizing grain crops there are
maximum of 20% free moisture in Queensland, and a limits to how much can be applied at sowing, and it
minimum of 17% S and 21% Ca in Victoria. may be necessary to apply part of the N before sowing.
Other crops may require post-sowing applications,
particularly of N.
Elemental (Raw) Sulfur
The grade of elemental (raw) S in any fertilizer must Various techniques for calculating fertilizer and
comply with the following standards for particle size in nutrient application rates and methods that can be
most States: used to compare the relative costs of different fertilizer
product combinations are set out below.
(a) Fine grade less than 0.25 mm;
(b) Medium grade 0.25 to 0.5 mm; Fertilizer application rate calculated from
recommended nutrient rate (per hectare)
(c) Coarse grade more than 0.5 mm.
Required Nutrient rate 100
In Victoria, where sulfur particles are intended for Required fertilizer rate = ---------------------------------------------------------------------
Fertilizer Analysis (%)
ground application, at least 50% of the sulfur particles
must be able to pass through a 0.25 mm sieve and in the e.g. to apply 75 kg/ha of N as urea (46% N), the
case of aerial application, not more than 30% of sulfur fertilizer rate will be:
particles must be able to pass through a 0.25 mm sieve.
75 100
--------------------- = 163 kg/ha
46
Warning Statements on Labels or
Advice Notes for Fertilizers The recommended rate to apply should be rounded,
e.g. to 160 kg/ha.
Warning statements must be shown on labels or advice
notes as required by regulation in each State. Nutrient rates applied calculated from fertilizer
These may relate to possible adverse effects in certain application rates
situations, limitations of use or effectiveness, or health
Fertilizer Rate Analysis
precautions. Nutrient rate = -------------------------------------------------------------
100

Calculating Fertilizer and Nutrient e.g. if 200 kg/ha of superphosphate (8.6 % available P)
is applied, 17.2 kg P/ha will be applied
Application Rates
Most recommendations for fertilizer uses are expressed 200 8.6
---------------------- = 17.2 kg available P/ha
as recommended rates for application of the individual 100
nutrients, e.g. 10 kg P/ha plus 60 kg N/ha. The user
must then convert these to rates of fertilizer product.
The choice of fertilizer product may be determined by a Nutrient/Product Rate Ready Reckoners
number of factors, including the services provided by Ready reckoners for calculating fertilizer and nutrient
various suppliers, local availability, timing of split rates for various product analyses and a range of
applications, and the most cost effective combination application rates are set out in Tables 13.3 and 13.4.

Table 13.3 Ready reckoner for calculating fertilizer product application rates.
Nutrient Product rate required for various level of nutrient content %w/w
rate kg/ha 5 8.6 10 11 12 15 18 20 21 34 38 41 46 50 82
1 20 12 10 9 8 7 6 5 5 3 3 2 2 2 1
2 40 23 20 18 17 13 11 10 10 6 5 5 4 4 2
3 60 35 30 27 25 20 17 15 14 9 8 7 7 6 4
4 80 47 40 36 33 27 22 20 19 12 11 10 9 8 5
5 100 58 50 45 42 33 28 25 24 15 13 12 11 10 6
10 200 116 100 91 83 67 56 50 48 29 26 24 22 20 12
20 400 233 200 182 167 133 111 100 95 59 53 49 43 40 24
25 500 291 250 227 208 167 139 125 119 74 66 61 54 50 30
30 600 349 300 273 250 200 167 150 143 88 79 73 65 60 37
40 800 465 400 364 333 267 222 200 190 118 105 98 87 80 49
50 1000 581 500 455 417 333 278 250 238 147 132 122 109 100 61
100 2000 1163 1000 909 833 667 556 500 476 294 263 244 217 200 122
In the above table to apply 20 kg of P/ha using MAP (21% P), 95 kg of MAP is required. To apply 40 kg of K/ha using potassium nitrate (38% K), 105 kg of
potassium nitrate is required.

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Table 13.4 Ready reckoner for calculating nutrient application rates.


Product Nutrient (kg/ha) supplied at various analyses (%)
rate kg/ha 5 8.6 10 11 12 15 18 20 21 34 38 41 46 50 82
5 0.25 0.43 0.5 0.55 0.6 0.75 0.9 1 1.05 1.7 1.9 2.05 2.3 2.5 4.1
10 0.5 0.86 1 1.1 1.2 1.5 1.8 2 2.1 3.4 3.8 4.1 4.6 5 8.2
15 0.75 1.29 1.5 1.65 1.8 2.25 2.7 3 3.15 5.1 5.7 6.15 6.9 7.5 12.3
20 1 1.72 2 2.2 2.4 3 3.6 4 4.2 6.8 7.6 8.2 9.2 10 16.4
25 1.25 2.15 2.5 2.75 3 3.75 4.5 5 5.25 8.5 9.5 10.3 11.5 12.5 20.5
30 1.5 2.58 3 3.3 3.6 4.5 5.4 6 6.3 10.2 11.4 12.3 13.8 15 24.6
40 2 3.44 4 4.4 4.8 6 7.2 8 8.4 13.6 15.2 16.4 18.4 20 32.8
50 2.5 4.3 5 5.5 6 7.5 9 10 10.5 17 19 20.5 23 25 41
75 3.75 6.45 7.5 8.25 9 11.3 13.5 15 15.8 25.5 28.5 30.8 34.5 37.5 61.5
100 5 8.6 10 11 12 15 18 20 21 34 38 41 46 50 82
200 10 17.2 20 22 24 30 36 40 42 68 76 82 92 100 164
300 15 25.8 30 33 36 45 54 60 63 102 114 123 138 150 246
500 25 43 50 55 60 75 90 100 105 170 190 205 230 250 410
In the above table urea (46% N) applied at 75 kg/ha supplies 34.5 kg N/ha. Superphosphate (8.6% available P) applied at 200 kg/ha supplies 17.2 kg P/ha.

Conversion of Fertilizer Rates Per To make calculations for the number of trees per
Hectare to Rates Per Metre of Row. hectare use the following formula:
Depending on the type of application equipment and 10000
Number of trees/ha = ----------------
calibration method required, there are several ways to WD
calculate the rate of application for different row
intervals. W = Width between rows (metres). D = Distance
between trees within the row (metres).
kg/ha row spacing (in cm)
Grams (g) per metre of row = -------------------------------------------------------------------
1000 Conversion of fertilizer rates per hectare to rates
kg/ha row spacing (in cm) per square metre.
Grams (g) per 20 metre of row = -------------------------------------------------------------------
50 To convert from kg/ha to grams (g) per square metre
(m2) divide the rate by 10.
kg/ha row spacing (in cm)
Kilograms (kg) per 100 metre of row = -------------------------------------------------------------------
10000 2 kg/ha
g m = -------------
10
Table 13.5 shows the length of row per hectare at
different row widths. Conversely to convert rates per square metre multiply
the rate by 10.
Table 13.5 Length of row/ha by row width.
2
Row width Metres of row/ha kg/ha = g m 10
18 cm (7) 55 555
23 cm (9) 43 478
Fertigation
36 cm (14) 27 778
72 cm (28) 11 364
Fertigation is the application of fertilizers dissolved in
irrigation water. It provides another means of applying
100 cm (40) 10 000
fertilizer nutrients to the soil and can be used to
Table 13.6 shows the number of trees per hectare for complement or replace application in other ways, i.e.
orchard or plantation tree crops at various row and tree dry application through tractor-drawn equipment.
spacings. Mostly, fertigation is used to supplement the overall
fertilizer program. It is most commonly used in tree
Table 13.6 Trees/ha by row width and tree spacing. crops and for post-plant application of fertilizers in
Row Spacing between trees in row (m) annual crops. Those nutrients which are most mobile
width in the soil, i.e. N, K, sulfate-sulfur (SO42), magnesium
(m) 2 3 4 5 6 7
(Mg), and boron (B) are most suited to fertigation.
3 1 667 1 111 833 667 556 476 Well designed and operated irrigation systems allow
4 1 250 833 625 500 417 357 water and nutrients to be placed in the zone of greatest
5 1 000 667 500 400 333 286 root activity, permitting rapid utilization by plants.
6 833 556 417 333 278 238
With the necessary equipment, fertigation is easy and
7 714 476 357 286 238 204
convenient and can save time, labour, machinery and
8 625 417 313 250 208 179 maintenance costs, and fuel. Soil compaction can also
9 556 370 278 222 185 159 be minimised by reducing the number of passes with
10 500 333 250 200 167 143 wheeled equipment.

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HANDLING AND USING FERTILIZERS

Fertigation is particularly suited to those situations Fertilizers suitable for use in fertigation
where there is a need to split the nutrient usage into a There are many different fertilizers which are suitable
number of applications during the growing season, as it for fertigation, some of which are marketed specifically
is possible to apply the fertilizer on a more regular basis for application in this way.
than is practical where other application methods are
used. Under certain conditions, this may allow better Overseas, in Europe and North America, there is a
recovery and utilization of applied plant nutrients, wider product choice, reflecting the larger scale and
particularly where leaching is possible. Soils differ in more intensive nature of their agriculture. With the
their ability to hold nutrients, with leaching losses most exception of some nitrogen fertilizers, most of the
likely to occur on sandy soils. products which are used in fertigation systems in
Australia are imported.
Uniform water application is important, through good
design and system maintenance, to allow even fertilizer Not all fertilizers are suitable for fertigation, the reasons
application. So too is accurate irrigation scheduling to being:
minimize over-watering, which may result in nutrient (a) the fertilizer is insoluble, e.g. oxides;
loss and soil acidification.
(b) the fertilizer contains insoluble impurities,
With fertigation, nutrients may be lost past the root granulation or coating agents, which may block
zone on cracking clays when surface (flood) irrigated, if filters, nozzles and emitters, e.g. granular
water (and dissolved fertilizer) flows down cracks and phosphorus fertilizers such as DAP and MAP
continuous large pores (old root paths). which are intended for dry application to the soil;
Fertigation can often be performed when other types of (c) the fertilizer has a coarse particle size and takes a
application are not possible, such as when aerial long time to dissolve. Soluble fine or solution
application is not possible due to bad weather or the grade products, which dissolve more quickly, are
soil is too wet to carry agricultural equipment. This available. Coarse granular and prilled products
may necessitate watering just to apply fertilizer, but can be used, provided they do not contain
prevents deficiencies from occurring. excessive amounts of impurities. They do require
Fertilizers can be applied through most irrigation more agitation.
systems, e.g. flood, furrow, sprinkler, drip and trickle Soluble fertilizer salts vary in their solubility and
systems and through fixed line and travelling systems. dissolution rate (speed with which they dissolve);
With travelling systems, the fertilizer solution needs to muriate of potash and potassium nitrate for example,
be injected continuously at a controlled rate. are more soluble and therefore often used in preference
Fertilizer solutions can be introduced into irrigation to sulfate of potash. If the particle size is comparable,
water in various ways, including gravity feed systems fully hydrated salts, e.g. zinc sulfate heptahydrate, will
near head ditches for flood and furrow irrigation, dissolve more quickly than less hydrated salts, e.g. zinc
suction devices on the inlet side of centrifugal pumps, sulfate monohydrate.
pressure differential (venturi) systems on the outlet Overseas, use is made of fertilizer solutions in fertigation
side of pumps, or high pressure injectors which programs, e.g. polyphosphates and potassium
introduce the solution into the main at a higher thiosulfate, but these products are either not available or
pressure than that present in the sprayline. are available only in limited quantity in Australia.
Specialist advice should be sought from the suppliers of
irrigation equipment in choosing and setting up a Formation of precipitate
fertigation system. When preparing fertilizer solutions containing two or
more different fertilizer salts for injection into
Fertilizers are corrosive. Mixing tanks should therefore
irrigation lines, it is possible that precipitate (sediment)
be made of polypropylene, fibreglass, or stainless steel.
may form. This occurs if reaction products form which
Avoid the use of mild steel.
are either insoluble or less soluble than the original
Plastic fittings (nylon or polypropylene) are adequate products. The resultant precipitate may settle to the
for fertilizers, but if agricultural chemicals are to be bottom of the mixing tank or block filters and emitters.
injected as well (not a common practice in Australia), Precipitate may also form if the water is hard (high in
stainless steel is recommended. Ca and Mg), alkaline (high pH), or contains carbonate.
Fertilizers can corrode copper and copper alloys Nitrogen and potassium fertilizers such as urea,
(brass), e.g. nitrate solutions. As electric motors ammonium nitrate, muriate of potash, and potassium
contain copper wiring and internal combustion nitrate should not cause precipitate to form.
engines use copper fuel lines, these should be protected Anhydrous ammonia will cause insoluble calcium and
from irrigation spray, e.g. from centre pivots. magnesium compounds to precipitate in hard water.
Fertigation injectors should be flushed after use to Reaction products may form when phosphate, sulfate,
prevent scale forming and extend the life of gaskets and calcium, magnesium and micro-nutrient fertilizers are
metals. used in solution.

121
AUSTRALIAN SOIL FERTILITY MANUAL

If precipitate or scale is likely to form, it may be best to These figures are for saturated solutions and are
seek alternative application methods. Blockages result maxima. They are presented for comparative purposes.
in inefficient application of water and nutrients and It is not practical to achieve these concentrations on
consume time. Scale formation may shorten the life of farm. No more than one-half of these concentrations
equipment, which is costly to replace. (or perhaps one-quarter for products which cause the
temperature to fall) should be used when preparing
In those situations where precipitate is likely to form,
fertilizer solutions.
fertilizer solutions should be prepared immediately
prior to use. Do not allow to stand for an extended
period of time, e.g. overnight, as this increases the risk Calibration of Equipment
or amount of precipitation and the settling of sediment Most manufacturers supply information about how to
in the bottom of mixing tanks. calibrate equipment. If more accurate calibration is
Note: Nutrient-enriched irrigation water may also required, this can be achieved by one of the following
result in increased microbial activity, causing blockages methods:
in irrigation lines and emitters in trickle irrigation
systems. Method 1:
Measure the distance covered (D) in metres to apply a
Solubility known quantity (Q) in kg of fertilizer (e.g. 50 kg).
The following rules of thumb, to be applied in the
order given, are useful in determining the solubility of Method 2:
fertilizer salts in water, although there may be Remove the delivery hoses from the application tynes
exceptions. and collect and weigh the fertilizer in kg (Q) applied
over a measured distance (D) in metres (e.g. 50
(a) All ammonium, nitrate, K, sodium (Na) and Cl metres).
salts are soluble;
The application rate in kg/ha, for either method, can
(b) All oxides, hydroxides and carbonates are then be calculated as follows
insoluble;
10 000 Q (kg)
(c) All sulfates are soluble except for calcium sulfate; Application Rate (kg/ha) = --------------------------------------
D (m) W (m)
Using these rules, calcium nitrate is soluble (rule A). where W = width of the applicator in metres.
Calcium carbonate and magnesium carbonate are
insoluble (rule B). Magnesium sulfate is soluble but For row crop planters, W is the (number of rows) x
calcium sulfate isnt (rule C). (row spacing).
The solubility of various compounds in water is shown Where it is necessary to change the setting on cog or
in Table 13.7. chain drives, the following cog size calculations can be
used:
Table 13.7 Solubility of various fertilizers in water
(kg/100 L at 20C).
Wheel Cogs:
Chemical Name Formula Solubility**
Urea CO(NH2)2 105 Number of teeth required =
Ammonium nitrate NH4NO3 192 Required Rate (kg) Present Number of Teeth
----------------------------------------------------------------------------------------------------------------
Ammonium sulfate (NH4)2SO4 75 Present Rate (kg)
Monoammonium NH4H2PO4 37
phosphate Outboard Cogs:
Potassium chloride KCI 34
Number of teeth required =
Potassium nitrate KNO3 32
Present Rate (kg) Present Number of Teeth
Potassium sulfate K2SO4 11 ------------------------------------------------------------------------------------------------------------
Required Rate (kg)
Calcium nitrate * Ca(NO3)2.4H2O 129
Magnesium sulfate Mg SO4.7H2O 71 Note: Calibration must be carried out under normal
Solubor Na2B8O13.4H2O 9.5 operating conditions (speed, gear, engine load), with
Copper sulfate Cu SO4. 5H2O 32 the implement in the ground, to avoid variations in
Iron sulfate FeSO4.7H2O 48
wheel slip.
Manganese sulfate MnSO4.7H2O 115
Zinc sulfate ZnSO4.7H2O 44 Care of Application Equipment
Sodium molybdate Na2MoO4.2H2O 65 Fertilizers are corrosive.
*Note: Hydro Calcium Nitrate has the formula 5Ca (NO3)2.
NH4NO3.10H2O, and a solubility of 250 kg/100 L at 200C. Follow equipment manufacturers' recommendations
**Solubility in kg/100 L water at 20C. closely.

122
HANDLING AND USING FERTILIZERS

Clean bins, augers and applicators after use and oil To calculate the fertilizer cost ($/ha):
where recommended.
Required Nutrient Rate (kg/ha) Fertilizer Price ($/t)
--------------------------------------------------------------------------------------------------------------------------------
Most fertilizers are corrosive to steel. Ammonium Fertilizer Analysis (%) 10
nitrate and muriate of potash are corrosive to brass.
What is the cost of urea using the prices in Table 13.8
Many factors influence how corrosive a fertilizer is, e.g.; and an application cost of $20/tonne? At a rate of 40 kg
its pH, presence of free acids, and whether it is an ionic N /ha, it is as follows
compound, and if so, the ions it forms; its
40 $420
hygroscopicity, or tendency to absorb moisture. ------------------------ = $36.52/ha
46 10
Additives and coatings are added to fertilizer to reduce
its hygroscopicity. The critical relative humidity of
some common fertilizers is shown in Table 13.1. The Comparing nutrient costs in multiple nutrient
lower the figure, the more likely the product is to fertilizers.
absorb atmospheric moisture. This can be calculated in one of two ways:
1 A cost is allocated to one of the nutrients (based on
Costing the Value of Different Fertilizer other commercially available single nutrient
Products fertilizers), and the residual cost allocated to the
Fertilizers vary in their individual nutrient content and other nutrient. (See Example 1).
in the number of different nutrients that they contain. 2 Alternatively, the value of the multi-nutrient
The choice of fertilizer will depend on a number of fertilizer can be costed using the nutrient costs of
factors, including the agronomic suitability of the single nutrient fertilizers, and this value then
product, the cost of application, convenience of compared to the true price of the multi-nutrient
application, and availability. fertilizer. (See Example 2).
Where products are interchangeable, it will be useful to Examples using Urea (46%N), DAP (18% N, 20% P),
compare relative nutrient costs of alternative products. and triple superphosphate (TSP) (21% P), with the
hypothetical prices as shown in Table 13.8.
Some convenient methods of calculating relative costs
of nutrients supplied by different products are set out Example 1:
below.
Nutrient Costs:
In the examples provided, the hypothetical fertilizer
$400
prices used are shown in Table 13.8. These prices are N in Urea ------------------ = $0.87/kg N
46 10
for calculation of prices given in the example only and
are not taken from any particular source or location. $450
P in TSP ------------------ = $2.14/kg P
21 10
Table 13.8 Hypothetical prices used in examples.
Product Cost/tonne
Relative cost of P in DAP =
Urea $400
DAP $500 Cost of DAP (N analysis 10 Cost/kg on N in Urea)
----------------------------------------------------------------------------------------------------------------------------------------
P analysis 10
TSP (triple superphosphate) $450
Using the cost in Table 13.8:
Comparing single nutrient fertilizer costs. $500 ( 180 $0.87 )
--------------------------------------------------- = $1.71/kg of P
200
$/tonne (applied)
--------------------------------------------------------------
nutrient analysis (%) 10
Relative cost of N in DAP =
For example, the applied costs of urea using the
Cost of DAP (P analysis 10 Cost/kg on P in TSP)
hypothetical prices and an application cost of $20 per ------------------------------------------------------------------------------------------------------------------------------------
N analysis 10
tonne is $0.91 /kg of applied nitrogen
Using the cost in Table 13.8:
$400 + $20 (application cost)
---------------------------------------------------------------------- = $0.91
46 10 $500 ( 200 $2.14 )
--------------------------------------------------- = $0.40/kg of N
180
When costing P fertilizers it is important to decide
whether to base the calculation on the their total P This example assumes all products have the same
content or their available P content. In many soil application costs per nutrient and shows DAP is a
situations, the citrate insoluble portion will not be relatively less expensive source of nitrogen and
available for plant growth. phosphorus than the single nutrient products.

123
AUSTRALIAN SOIL FERTILITY MANUAL

Example 2: recommendations and show no signs of


N cost as Urea = $0.87/kg N deformation or deterioration;
P cost as TSP = $2.14/kg P (c) the hooks, bars, or forklift truck tines employed
for lifting should have rounded edges or be
Value of DAP at straight nutrient costs: protected by wrapping;
N 180 0.87 = $156.60 (d) the stability of the load is checked when the FIBC
P 200 2.14 = $428.00 is to be moved or stacked on a pallet;

Total Value = $584 (e) the stated load weight is checked against the safe
working load (SWL) before lifting it; and
In this example, DAP costs $84/t ($584 $500) less
than purchasing an equivalent amount of N and P as (f) the forklift is confirmed to have adequate capacity
the straight products, urea and TSP. to carry suspended load.

If, however, the cost of DAP was more than purchasing In addition to these guidelines the following
the equivalent amount of N and P as the single nutrient procedures are recommended: -
products, urea and TSP, it then has to be considered if stacking two high, pack FIBCs in a pyramid
whether this additional cost will be offset by savings in fashion on good, dry hardstand;
application costs or agronomic benefits.
ensure that the FIBC does not protrude beyond the
pallet;
Occupational Health
when lifting always attach the lifting device to all of
Physical handling the lifting points provided on the FIBC ensuring
Packaged fertilizers for use in agriculture and the load is evenly spread;
horticulture vary in size from several kilograms, in the
case of some micro-nutrients, up to 1 tonne in the case if using a lifting frame, use locked hooks;
of flexible intermediate bulk containers (FIBC) for tilt the mast of the forklift rearward when lifting or
large-scale users. The packaging weights of most moving a FIBC;
concern are those in the 1655 kg size, as these are often
handled manually and incorrect handling can lead to do not stand directly under a suspended FIBC;
muscle and skeletal strain and injury. always use a safety frame when emptying a FIBC.
Packages 16-55 kg size
Dust
The National Occupational Health and Safety Dust exposure is the most common Occupational
Commission has issued a National Code of Practice for Health issue in the handling of fertilizers.
Manual Handling [NOHSC 2005:(1990)] which
provides advice and guidelines for manual handling. The following precautions must be taken with all
The Code notes that as weight increases from 16 kg to products.
55 kg, the percentage of healthy adults who can safely
Avoid inhaling dust;
lift, lower or carry the weight decreases and states that
mechanical assistance and/or team lifting Avoid contact with eyes and skin;
arrangements should be provided to reduce the risk of
Wash hands after use;
injury associated with these heavier weights. It also
states that no person should be required to lift, lower or Refer to the Material Safety Data Sheet (MSDS).
carry loads above 55 kg unless mechanical assistance or
team lifting arrangements are provided to reduce the The following general precautions are extracted from a
risk of injury. typical MSDS for most commonly used fertilizers
which are not classified as dangerous goods:
Flexible intermediate bulk containers (FIBC)
Guidance for the use of FIBCs are outlined in Engineering controls
Australian Standard AS 3668 1989. Avoid generating and inhaling dusts. Use in
well-ventilated area. Keep containers closed when not
AS 3668 states that before lifting any filled FIBC, it is in use.
important that:
Personal protection
(a) it is inspected for any damage which may render it
Avoid eye contact and repeated or prolonged skin
unsafe;
contact. Wear overalls, safety glasses, and impervious
(b) the lifting loops, or other lifting devices are gloves. Avoid generating and inhaling dusts. If dust
positioned according to the manufacturers exists, wear dust respirator meeting the requirements of

124
HANDLING AND USING FERTILIZERS

AS/NZS 1715 and AS/NZS 1716. Always wash hands copper (Cu), boron (B), selenium (Se) and zinc (Zn)
before smoking, eating, drinking, or using the toilet. compounds. Users should observe the safety
precautions contained on the labels. Refer to the
Anhydrous ammonia Material Safety Data Sheet available from the
Anhydrous ammonia is a liquefied gas, stored and manufacturer or supplier for further information.
applied under pressure. If it is accidentally released, it
forms a poisonous gas. It should only be handled by Liming materials
specifically trained personnel. Anhydrous ammonia is Burnt lime (calcium oxide) and slaked lime (calcium
classified as a Dangerous Good and is subject to hydroxide) are highly alkaline substances and are
regulations under State Occupational Health and particularly corrosive to eyes and soft skin and tissue.
Safety and Transport of Dangerous Goods regulations. Users should avoid exposure by wearing appropriate
Refer to the Material Safety Data Sheet available from protective equipment. Refer to the Material Safety Data
the manufacturer or supplier for further information. Sheet for further information.
Nitrate fertilizers Acknowledgements: This chapter has drawn on
Many are classified as oxidising agents. They can information provided by Incitec Ltd from their internal
decompose in fire, causing the fire to burn fiercely, and documents for dealer training, Material Safety Data
release toxic nitrogen oxide gas. Oxidising agents are Sheets, and Information Bulletin on Fertigation (July
classified as Dangerous Goods and are subject to 1998) and has quoted extensively from the Fertilizer
regulations under State Occupational Health and Manual 1998, edited by United Nations Industrial
Safety and Transport of Dangerous Goods regulations. Development Organization and International Fertilizer
Oxidising agents such as potassium nitrate and Development Center. FIFA is grateful to these
ammonium nitrate can produce an explosive mixture organisations for permission to use their material.
with diesel fuel or other carboniferous material. Refer
to the Material Safety Data Sheet available from the
manufacturer or supplier for further information. References
Fertilizer Manual. (1998). Edited by United Nations
Micro-nutrient fertilizers Industrial Development Organization and
Some micro-nutrient fertilizers are classified as poisons International Fertilizer Development Center, Kluwer
i.e. they are toxic to humans, if ingested, e.g. many Academic Publishers Dordrecht, The Netherlands.

125

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