Design of Prilling Tower

Urea Physical Properties

T o=132.6 ℃

i=224,457 J∗kg−1

ρ1=¿1230 kg∗m −3
( 133℃ )¿

ρ s=1335 kg∗m−3 (20 ℃)

c 1 = 2,098 J *kg−1∗K −1 (132.6℃ )

c s = 1,748 J *kg−1∗K −1 (25−132 ℃)

λ 1=0.83 W∗m−1∗K−1 (80 ℃ )

λ s = 1.19 W *m−1∗K −1 (Boretzky , 1967)

μ1 = 2.16 ×10−3 N∗sec ¿ m−2 (80 ℃ )

Air Physical Properties (36.1℃ )

ρ g=¿ 1.14 kg *m−3

c g=1008 J∗kg−1∗K −1

μ g=1.90∗10−5 N∗¿ sec *m−2

λ g= 0.0268 W * m−1∗K −1

1. Heat Balance

J J J
44301.420{2098 (135 – 132.6) + 224457 + 1748 (132.6-60)}
kg∗K kg kg∗K

kJ
=15,788,893.18 =¿4385.80 kW
hr
2. Airflow required

Heat gained by air = Heat released by urea

15,788,89 3.18=m air∗c g∗∆ T

15,788,893.18
= 783,179.225 kg * h r −1 = 689,999.32 m3∗hr −1
1.008∗20

3. Tower diameter

An upward air superficial velocity of 1.2 m * sec−1is taken.

686999.32∗4
D=
√ π∗1.2∗3600
= 14.5 m

Take a tower diameter of 14.5 m leading to an air superficial velocity of 1.156 m * sec−1 .

4. Terminal velocity

d p= 1.5 * 10−3 m

Assume v r = 6.3 m * sec−1

1.14∗6.3∗1.5∗10−3
Re = = 567
1.90∗10−5

c w = 0.58 (see Fig. 5.7)

Fig C w vs ℜ
Terminal velocity of particle

π 3 d 2 ∗1
d p ( ps −p g ) g = c w π p p g v 2r
6 4 2

π
(1.5 * 10−3 ¿3 (1335 – 1.14) 9.81 = 2.311 * 10−5
6

π −3 2 1 2 −5
0.58 * (1.5 * 10 ¿ ∗1.14∗6. 3 =2.317∗10
4 2

So, LHS = RHS

v a=vr −superficial velocity ¿ new diameter

v a=4.5−0.47=4.0 m∗sec −1

5. Heat transfer coefficient

Re =567

μ g c g 1.90∗10−5∗1008
Pr = = =0.7146
λg 0.0268

1 1
2 3
N u=2+ 0.552∗ℜ ∗Pr

1 1
N u=2+ 0.552∗567 2∗0.7146 3 =13.75

α o dp
Nu= =¿ 13.75
λg

λg 0.0268
Heat transefer coefficient α o= ∗13.75= ∗13.75=245.68W /m2∗K
dp 1.5∗10−3

6. Solidification time

i+c 1(T −T ) 224457+2098(135−132.6)

Ph = f o
= =1.345
c s (T o−T c ) 1748(132.6−35)
 α o d p 245.68∗1.5∗10−3
Bi = = =0.1548
2 λs 2∗1.19

Fo = Ph ( 16 + 3 1Bi )=1.345 ( 16 + 3∗0.1548

1
)=3.1203
λs 1.19
a= = =5.1∗10−7
c s p s 1748∗1335

Fo∗¿d 2

t s 1= p
=3.1203 ¿ ¿ ¿
4a

τ E / τ E , min =1.28 ( see Fig .5 .10 )

Fig Correction factor for the

solidification time. (From VDI, 1993.)
 τE
Corrected solidification time t s 2= ( )
τ E ,min
∗t s 1=1.14∗3.44=3.9216 sec= 4 sec 7. Tower

height for solidification

¿ v a∗t s 2=5.144∗3.9216=20.1727 m

8. Prill cooling time

dp −4
R= =7.5∗10 m
2

1
2
=7236.151W −1∗K
α0 R

2(R−R /2) 2(7.5∗10−4−3.75∗10−4 )

2
= 2 −8 = 1120.448
λs R 1.19∗7.5 ∗10

1 1 2(R−R /2)
2
= 2
+ =7236.151+1120.448=8356.599
kc R α 0 R λs R2

1
k c= 2 −8
=212.739W .m−2∗k −1
8356.599∗7.5 ∗10

ρs c s dp 70−20 1335∗1748∗1.5∗10−3 132.6−35

Cooling timet c = ∗ln = ∗ln
6 kc 30−20 6∗212.739 60−35

¿ 3.7350 sec=4 sec

9. Prill cooling height

= 3.7350 * 5.144 = 19.212 m

10. Total tower height

= Height required for solidification + Height required for cooling of solidified product

= 20.1727 + 19.212

= 39.38554 m, take 40 m