Prilling and Granulation

Thanks to Our respected Sir,
Assistance Professor Mudassar

Azam
Prilling
&
Granulation
Presenters;
Syed
Ibrar Naqvi
Syed Kazim Raza
Objectiv
e
The Main objective of our
presentation is to give you details of
Granulation and Prilling.
Contents
Whats a Prill?
Whats Prilling?
Why is prilling required?
Which industries use Prilling Process?
Brief description of Prilling Tower.
Whats Granulation?
Reasons for Granulation.
Uses of Granulation
Types of Granulation
Comparison of Prilling and Granulation
Priority of different fertilizers industries of Pakistan
The First thing that pops to our mind when we

read/hear the topic of the presentation is that What is ,
Prilling
Granulation
What is Prill & Granules?

APrillis a small aggregate of a
material, most often a dry
sphere, formed from a melted
liquid during an industrial
process.
A Granule is small particles

gathered into a larger,
permanent aggregate in which
the original particles can still be
identified
Prilling
Prilling
The
solidification of droplets
of molten material falling
against an upward stream of
air
It
is used in the
manufacture of ammonium
nitrate and urea fertilizers
Prilling
is a technology used
to produce prills with a
diameter of a few millimetres
back
Another Definition
Method
to produce reasonably uniform

spherical particles from molten solids, strong
solutions or slurries.
It
essentially consists of two operations;

1.
Producing liquid drops
2.
Solidifying them individually by cooling

as they fall through a rising ambient air
stream
Why Prilling?
It
is more convenient for use, storage, and

transportation because of their much smaller
specific surface area and larger bulk density.
Prills
of ammonium nitrate and urea are

smooth, spherical, has less dust, and
moderately rigged, but usually are smaller
and more fragile than granulated fertilizers.
Which Industries use Prilling Technology?

[Agro
Chemicals] or Fertilizer Industries

UREA, Ammonium Nitrate and NPK Fertilizers
Explosive
Industries
Synthetic
Detergents Industries
Food
Prills
Industries
have also been used to protect active

ingredients from exposure to environmental
factors and to cover up the flavor of
bitternutraceuticals.
Where is Prilling done?

Prilling
process is an industrial process and it

is done in special constructed devices known
as;
Prilling Towers
Prilling tower
Requirements for a Prilling Tower

Must
be of sufficient height for the particles to be strong

enough not to break on impact.
Fertilizer
industry Prilling towers are typically over 50 m high
Significant
amounts of water required to increase the

cooling effect on the drop.
Temperature
in the tower should be low.
Construction of Prilling Tower

It is a cylindrical vertical tower with average
height of 75m, in which urea prilling takes
place. It consists of prill section the top and
scrapper at bottom. Prill tower contains
bottom
lowers(window)
and
top
lowers(windows) also. In the prill section
bucket is there. The tower is coated inside
with anti corrosive plant. This is a natural
draft Prill tower.
It consists
perforated.
of
prill
bucket
Molten
liquid
is
showered
perforated prill bucket.
which
form
is
the
Solid droplets are formed by the action of
Condition for Prilling a

Substance
The material to be prilled must be a solid at room temperature and a low

viscosity liquid when melted.
Prills are formed by allowing drops of the melted prill substance to congeal or
freeze in mid-air after being dripped from the top of a tallprilling tower.
Melted material may also be atomized and then allowed to form smaller prills
that are useful in cosmetics, food, and animal feed.
The melt must be sprayed into droplets with uniform size as requested;
The sprayed droplets must be fully solidified and cooled in order to avoid
bonding of particles with each other and caking on the wall, and to ensure that
the product collected at the bottom can be packed directly.
Prilling Tower
Cleaned Air
30
Cyclone
Prilling
Tower
Bag House
27
Urea Melt (99.8%)
Pump
Melting Furnace
Dehumidifier
Air from Atm
Screen
29
Prilled Urea (99.8%)
28
PRILLING TOWER:
PRILLING
TOWER:
PRILLING TOWER:
PRILLING TOWER:
Granulation
GRANULATION
Granulation is the process in which primary

powdered particles are made to adhere to
form larger multi particles entities called
granules
Granules typically have a size range between

0.2 to 4.0 mm.
Granulation involves large range of

techniques to form agglomerates .
Competition of Prills from Granuels
The quality of prills is significant less than that of granules, the main
difference being the lower strength and smaller size of prills.
Research has shown that once a farmer has used granules, he will not
choose prills again, unless the price is lower.
Most new urea plants are large scale granulation plants and are located
in low feedstock areas; these plants are export driven and compete or
will compete with your prills.
Reasons for Granulation
Prills are too small and too weak; Prilling cause air pollution
and is more expensive than granulation
Granulation is done to prevent segregation of the constituents

of the powder mix
To improve the flow properties/fluidity of the mix
To improve the compaction characteristics of the mix
Avoid dustiness
Improve appearance
Granulation is done to
improve flow properties of the mix
improve compression properties of the mix
prevent segregation of components in powder mix
reduce production of toxic dust
reduce possibility of cake formation
increase convenience of transport
An important application of granulation is in improving the

flowability
(submicron) particles which stick together because of the

large surface forces acting in materials with very high
surface/volume ratios.
Uses of Granulation
The major use of granulation is in Pharmaceutical industry.
Uses in Chemical Industry

In the chemical industry, granulation refers to the act or
process in which large objects are cut or shredded and remelted
into granules or pellets. E.g.; Urea is converted into pellet form
through Fluid Bed urea granulation.
Uses in Pharma Industry

In the pharmaceutical industry, granulation refers to
the act or process in which primary powder particles
are made to adhere to form larger, multiparticle entities
called granules. It is the process of collecting particles
together by creating bonds between them. Bonds are
formed by compression or by using a binding agent.
Granulation
is
extensively
used
in
for
the
manufacturing of tablets, pellets (or spheroids).
Types of Granulation
1. Wet Granulation
2. Dry Granulation
back
Wet Granulation
It is the process of adding a liquid solution to powders, is one of

the most common ways to granulate. It involves the massing of a
mix of dry primary powder particles using a granulating fluid.
The fluid contains a solvent which must be volatile so that it can
be removed by drying, and be non-toxic. Typical liquids include
water, ethanol and isopropanol, either alone or in combination.
Fluidized bed Granulator
Wet Granulation
Dry Granulation
The
dry granulation process is used to form

granules without using a liquid solution
because the product to be granulated may
be sensitive to moisture and heat. Forming
granules without moisture requires
compacting and densifying the powders. In
this process the primary powder particles
are aggregated under high pressure.
Swaying granulator or high shear mixergranulator can be used for the dry
granulation.
Dry Granulation
Dry granulation equipment
sluggers
roller compactors
back
Sluggers
Dry granulation can be conducted under two

processes; either a large tablet (slug) is produced in
a heavy duty tableting press.
Roller Compactor
The powder is squeezed between two rollers to
produce a sheet of materials (roller compactor,
commonly referred to as a chilsonator).
Summary
In
the pharmaceutical industry, most

products are manufactured using the wet
granulation process. Wet granulation offers
a wide range of capabilities for forming
granules, from the production of light
granules to the production of very dense
granules. More than 70% of the global
industrys granulations are made using this
method.
Pharmaceutical products are processed all over the

world using the Wet Granulation or Dry Granulation
methods. Which method is chosen depends on the
ingredients individual characteristics and ability to
properly flow, compress, eject, and disintegrate.
Prilling
Granulation
In prilling tower hot molten liquid and

air moves in countercurrent fashion
in granulation powdered particles are

adhere to form larger multi -particle entites.
It don't involve any use of binders
It involves the use of binders
Its end product is hollow and size is not

uniform
End Product is solid and size is uniform
more tendency for caking and breakage
no breakage and less caking tendency
Operation is simple
operation is not simple . A lot of screening

and cyclone separator is required
It doesnt involves the agglomeration.
It involves the process of agglomeration.
less storage life
long storage life
Granulated Urea
Granular
urea is chemically the same as

prilled urea. Granular urea, however, is
slightly larger and harder. Today, the use of
prilled urea is more prevalent because it is
more resistant to breaking down when being
blended with the other components of
fertilize.
Sona Urea is in both Prills and Granule forms
back
Sarsabz Urea in Prills
Sarsabz Urea is available as prills that are

crystalline white and highly resistant to moisture
and thus facilitate long time storage as well.
Sarsabz Nitro phos is granulated form
Sarsabz can in Granulated
back
Babar Sher Urea

In both granular and prill forms
back
Engro
Urea in both granules and prills
CAN in Both
SSP powder and granules
SOP in powder and granuels
DAP-granular Form
Engro prill tower-125metres
Cost US$ 1.05 Billion
back
Revision
Whats Prilling?
Fauji Fertilizers Sona Urea is manufactured

in in prilled or Granuels form?
The Height of new built Engro Prilling tower?
Baber Sher Urea by DH is manufactured in

Granuels or Prills?
Sarsabz Urea in Granules or Prills?
The types of Granulation?
Which particles have more surface area

Granules or Prills?
Name of Dry Granulation Equipments.
Thank you for

your precious
time.

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What is the difference between prilling and granulation?

What is the difference between prilling and granulation?

What industries commonly use prilling?

What industries commonly use prilling?

Thanks to Our respected Sir,

Assistance Professor Mudassar

Why is prilling required?

Which industries use Prilling Process?

Brief description of Prilling Tower.

Reasons for Granulation.

Comparison of Prilling and Granulation

Priority of different fertilizers industries of Pakistan

The First thing that pops to our mind when we

What is Prill & Granules?

A Granule is small particles

to produce reasonably uniform

essentially consists of two operations;

Producing liquid drops

Solidifying them individually by cooling

is more convenient for use, storage, and

of ammonium nitrate and urea are

Which Industries use Prilling Technology?

Chemicals] or Fertilizer Industries

have also been used to protect active

Where is Prilling done?

process is an industrial process and it

Requirements for a Prilling Tower

be of sufficient height for the particles to be strong

industry Prilling towers are typically over 50 m high

amounts of water required to increase the

in the tower should be low.

Construction of Prilling Tower

Solid droplets are formed by the action of

Condition for Prilling a

The material to be prilled must be a solid at room temperature and a low

Urea Melt (99.8%)

Air from Atm

Prilled Urea (99.8%)

Granulation is the process in which primary

Granules typically have a size range between

Granulation involves large range of

Competition of Prills from Granuels

Reasons for Granulation

Granulation is done to prevent segregation of the constituents

To improve the flow properties/fluidity of the mix

To improve the compaction characteristics of the mix

improve flow properties of the mix

improve compression properties of the mix

prevent segregation of components in powder mix

reduce production of toxic dust

reduce possibility of cake formation

increase convenience of transport

An important application of granulation is in improving the

(submicron) particles which stick together because of the

The major use of granulation is in Pharmaceutical industry.

Uses in Chemical Industry

Uses in Pharma Industry

It is the process of adding a liquid solution to powders, is one of

Fluidized bed Granulator