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Prilled Fertilizer Production Line

Prilled Fertilizer Production Line

Prilling tower for fertilizer production

Prilling is an advanced manufacturing process that uses gravity and heat exchange to form compound fertilizers. A molten mixture of NPK raw materials is sprayed from the top of a tall tower (typically 80–110 meters) and cools as it free-falls, solidifying into hollow, spherical granules. This is a continuous process that doesn't use water, and it produces fertilizer with high water solubility and superior nutrient absorption.
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Prilled Fertilizer Production Line
Production Advantages
  • High production efficiency: Prilling is a continuous production process that allows for large-scale compound fertilizer manufacturing. The size and distribution of the sprayer nozzles can be adjusted to meet specific granule size requirements.
  • Relatively low energy consumption: The process uses the tower's height to achieve gravity-fed material descent and natural cooling, which significantly reduces the need for external power.
  • Stable product quality: Precise raw material ratios and an automated production process ensure that every batch is of stable and reliable quality.
Process Flow
Process Flow
Equipment Composition
  • Prilling tower:

    The tower is typically 80-110 meters high, with a steel or concrete structure that can withstand internal pressure from materials and airflow.

  • Granulation sprayers:

    Installed at the top of the tower, these are critical for determining the shape and size of the granules.

  • Heating and mixing devices:

    These devices melt and mix the raw materials. The heating component quickly heats the materials to their melting point, and the mixing device ensures a uniform blend.

  • Cooling system:

    This system consists of an air inlet at the bottom of the tower and an air outlet at the top. A fan draws cold air in from the bottom and pushes hot air out through the top, creating a stable airflow that ensures the granules cool and form quickly as they fall.

Advantages of the Finished Product (Hollow Spherical Granules)
  • Uniform and smooth granules As the liquid material solidifies during its free fall, it forms nearly perfect spherical granules that are uniform in size. This consistent shape and size make the product ideal for storage, transport, and application.
  • High strength The internal structure of the granules is dense, giving them high compressive strength and making them resistant to breakage. This reduces damage during handling and storage, ensuring product quality.
  • Even nutrient release The nutrients are evenly distributed within the granules. When dissolved in soil, NPK and other nutrients are released slowly at a set ratio, meeting a crop's needs during different growth stages and increasing fertilizer utilization.
Case Studies

Shenyang Lutian Fertilizer Co., Ltd.:
We provided a 200,000-ton/year fertilizer production line that is equipped with prilling tower.

Case Studies
Case Studies
Case Studies
Case Studies
Case Studies

108-meter prilling tower under construction

Case Studies
Case Studies
Case Studies
Case Studies
Other Fertilizer Manufacturing Line

The height and diameter of the tower are directly related to the required output. Larger outputs require a taller and wider tower.

After the raw materials are prepared according to the formula, a camera at the top of the tower monitors the consumption of the solution and the spraying of the rotating nozzles. This allows for timely intervention.

The inner wall of the tower is coated with a polyurea liquid for anti-corrosion protection.

All contact points between the pipes and the air are fully connected to a baghouse dust collector. A scraper conveyor is used for transportation.