Lecture 32

Processes for manufacturing compound fertilizers – Part 1

The processes for manufacturing compound fertilizers are discussed below

Steam/water granulation

In steam/water granulation process granules are formed by agglomeration. The solid raw
materials are proportioned (weighed) and usually premixed before being fed to the granulator
where agglomeration is initiated. In some plants, the raw materials are crushed either before or
after weighing to obtain a more uniform particle size distribution. In the granulator (usually a
rotary drum or a pug mill) steam and/or water or scrubber liquor is added to provide sufficient
liquid phase and plasticity to cause the dry raw materials to agglomerate into product size
granules. In some processes, the pug mill may be used to premix the solids and liquids prior to
the granulation in rotary drum unit. In other cases a small amount of ammonia may also be added
during granulation to react with the superphosphate to promote granulation and improve product
quality by decreasing the acidity and increasing the CRH. The moist and plastic granules are
dried, usually in a rotary drum type, fuel fired dryer and screened to remove the product size
fraction. The oversize material is crushed and recycled to the granulator along with the undersize
fraction. To ensure a uniform particle size distribution of the material returned to the granulator,
it is the best to return the crushed oversize material to the screening unit so that only material
passing the product screen recycled to the granulator. In some cases it is necessary to cool the
material before screening depending on the fertilizer grade and local conditions. If cooling is
required, it is usually performed in a rotary drum type unit that is very similar to the rotary dryer.
Fluid bed type coolers may be used to cool product size material, but they are not recommended
for cooling material having a wide particle size range.
 To atmosphere

Water
Water

Vent Oversize 
Phosphoric acid 
Crusers 

Raw Material  Water Dust  collection

Surge Hopper 
Ammonia Gas Scrubbing 
(Cluster of 6 
System 
Hoppers)  Product Screen

Preneutralizer Recycle Dehumi 

Batch Scale 
Vent Vent  Vent dification 
and Mixer  Vent
unit 
Phosphoric/Sulfuric
Continuous Feed  Acids Product Cooler
system  Rotary Drum
Ammonia
Granulator
Steam/water Conditioning Agent 
Soliod Urea  (Clay & Binder

Vent to Scrubber  Vent to 
Scrubber 

Fue 1
Conditioning 
Rotary Dryer  System  Product
Steam  Air Air Heater
Lump Breaker
Dehumidification
Urea Solution/Melt 
preparation System  Rotary  Air
Process 
Transfer Conveyor 
Cooler
(Belt‐ Type 

Fig. 1. NPK fertilizer granulation plant designed for maximum

flexibility in the use of raw materials, including Urea

Chemical granulation

Chemical granulation is the most complex method for preparing granular NPKs. The
chemical granulation process is similar to the previously described steam/water granulation
process except that most of the liquid phase required to achieve granulation is obtained by
reacting ammonia with phosphoric, sulfuric, and/or nitric acid. In some cases, a concentrated
solution of urea or ammonium nitrate may also be used. Some processes also involve a
significant reaction between ammonia and single or triple superphosphate (SSP or TSP). Much
of the ammonia acid reaction is often performed outside the granulator either in a tank type pre-
neutralizer or in a pipe type reactor. In many cases steam, water, scrubber liquor, and/or
additional ammonia and acid are also fed to the granulator to optimize the granulation
characteristics of each particular formulation. In most NPK chemical granulation plants, a
significant amount of solid raw materials is also used; therefore, the granules are formed
primarily by agglomeration. The relationship between the consumption of solid and liquid raw
materials is determined by a number of variables, including (1) required nutrient ratio (fertilizer
grade) and nutrient solubility requirements, (2) liquid phase requirements, (3) heat of reaction
and temperature limitations, and (4) process plant equipment capacity and operating features.
The granulation process also incorporates the design features recommended for the production of
NPKs containing relatively large amounts of urea or other very soluble and hydroscopic
materials.

Drop formation (Prilling)

The formation of NPK granules by prilling using nitro-phosphate type processing is

practiced quite widely. In this process the NPK mixture (solution) is concentrated to
approximately 96%-98% solids before it is introduced to the top of the prilling tower through
either a nozzle assembly or a perforated vessel referred to as a “prilling bucket”. The nozzle or
prilling bucket assemblies are designed to produce droplets of the “molten” fertilizer mixture
that, upon solidification, will yield the desired granule (prill) size. NPKs produced by the prilling
processes are very homogeneous with respect to the nutrient content. However, due to the
practical limitations of the drop formation and solidification process, prilled NPK products
usually exhibit a smaller particle (granule) size, typically 1.3 mm-3.0 in diameter, than do NPKs
produced by other granulation processes.

Compaction granulation

In this process mechanical force is used to form dense particles (granules) from finely
divided (non-regular) solid raw materials. With compaction granulation the dry materials are first
proportioned and thoroughly mixed (blended) to achieve the desired nutrient ratio (fertilizer
grade). This step of the process is identical to that normally used in the steam/water granulation
process. The mixture is then continuously fed to a pressure roll compaction machine that forms
the powdered mixture into a dense, hard sheet of material usually about 2-3 cm thick and 60-100
cm wide. The compaction machine consists of two horizontally opposed rollers that run inward
toward each other. The rollers may be as much as 100 cm wide and about the same diameter. The
shaft of one roller has a stationary shaft while the other is movable. Pressure is applied by a
hydraulic system to the movable roller shaft and bearing assemblies, which in turn determines
the pressing force applied to the fertilizer material fed to the machine. The compacted sheet of
material is crushed in a controlled manner to form smaller particles. The crushed material is
screened to obtain the desired product size fraction. The oversize material is crushed and
recycled to the screens and the undersize material is returned (recycled) to the compaction
machine after first being thoroughly mixed with the fresh raw material feed. No chemical
reaction is required for the process although the raw material properties (especially chemical
compatibility, thermal characteristics and plasticity) have a major influence on the performance
of the process. The pressing force of the compaction rollers required to produce an acceptable
granular product is measured in terms of tonnes of force per centimeter of roller width. Typical
pressing forces required for various fertilizer materials and mixtures.

Dust collector 

Air Atmosphare 

Bucket 
Elevator 
Paddle Mixer 

Two‐Deck 
Compactor  Conditioning Agent (clay & binder) 
Screen  Polishing 
Feed bin 
Drum 

Conditioner Drum 
Compactor  NPK Product 

Blucket  Screen  Raw Materials 

Coarse Crusher  Elevator 
Fine 
Raw Material 
Crusher 
Weighing,Mixing,and 
 
Continuous Feed System 

Fig 2. Typical NPK Fertilizer Compaction

l i l
Granular fertilizers prepared by compaction have a more irregular particle shape as compared
with the more smooth and rounded (spherical) granules produced by other granular processes.
The irregular particle surface and shape characteristics of compacted products may promote
caking during storage because of the generation of line during handling and because of the
increased surface area of the irregular particle compared with the more rounded granules
produced by other granulation processes. The irregular shape of compacted fertilizer granules my
cause some resistance among users who are accustomed to the more traditional spherical
fertilizer granules. However, experience has shown that market resistance to compacted products
can be largely overcome through refinements in the process, for example, tumbling/abrasion, to
round the rough edges and produce more spherical granules and through promotion and customer
education.