Granulation and Prilling

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Granulation and Prilling
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Granulation (lat. granulum - grain) is the process of substance forming into small particles (granules). Granulation enhances substances’ technological properties, prevents caking (agglutination) and increases flow properties, makes possible the application of material small amounts, facilitates loading, transportation, etc. Depending on the granulation method, one substance may acquire various hardness, hydraulic qualities, etc. 

NIIK offers chemical substances production process in a high speed drum granulator.

High speed drum granulator unit (HSDG) is applied for production of granulated fertilizers by dispersing a solution, melt or a suspension on a loose material curtain in a moving air medium in a rotating drum provided with internal blades.

The difference of HSDG from other existing drum granulators consists in increase of rotation frequency from 6-12 to 28-35 rpm. This allows to create granules curtain covering the entire cross section of the drum and to intensify the process. Unit filling factor increases from 15% to 75%. Rate of recycling decreases. The finished product is characterized by lower humidity and higher strength.

HSDG unit technical and economic performance

Paramete

Value

Capacity, t/h

10

Air, m3/t

1300-2000*

Water, m3/t

0-15*

Electric energy, kWh/t

35

Moisture removal from 1m3, kg/h

30

Length, m

10,6

Diameter, m

2,5

* - consumption depends on the type of granulated product.

HSDG unit technical and economic advantages

The range of produced products

The range of complex fertilizers produced by high speed drum granulator unit is very broad. NIIK has not carried out special technical studies aimed at HSDG produced granulated fertilizers diversification. Upon the customer’s request the company may perform experiments in order to explore the possibility of production of a certain fertilizer type by HSDG.

Product quality parameters

Parameter

Value

Main fraction, mm

3-5*

Main fraction content, % wt

min 95

Product temperature, 0С

45±5

* - may be changed (upon customer’s request).

 

HSDG unit application

Urea prilling technology

NIIK has been working on development of urea technology and improvement of urea prilling section since 1960s.

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Based on known-how and expertise NIIK developed the following methods of prilling process improvement:

Anti-caking agents by NIIK used for urea prills production.

 

Table 1 – Performances of the prilling tower, capacity 2000 TPD

Parameter

Value

Footprint of the prilling tower, m2

~ 500

Prilling tower height, m

80-114

Rotating equipment (crushers, rocking screens, fans, elevators, pumps etc.)

5 max.

Equipment washing

Once in 1-2 years

Maintenance engineer(s)

1

Table 2 – Technical and economical performances of the prilling tower operation

Parameter

Value

Air consumption for product cooling, t/t

13

Steam consumption for the tower, t/t

N/A

Cooling agent consumption, temp. 7-10 0С, t/t

N/A

Recycled product, % of the output

N/A

Power consumption for process needs, kW/t

15-18

Formaldehyde use

N/A,
on customer’s request only

Contaminants’ content in the air emitted to atmosphere after scrubber, mg/nm3:
- ammonia
- urea


40 max.
25 max.

Table 3 – Finished product properties

Parameter

Value

Product shape

spherical

Finished product quality:

Biuret content, wt. %;
Water content, wt. %;
Prills size distribution (main fraction), mm;

Content of main fraction, wt. %;
Static strength of prills, kgf/prills;
Product temperature, 0С

 

0,8-1,0
0,25-0,5
2,5-3,0

95 min.
1,0-1,3
for dpr. = 2,5-3,0 mm
40-50

Agglomerates

N/A

Product classifying

Not required

Advantages of a prilling tower:

Space saving design: easy to install.

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Services provided by NIIK for prilling towers