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Most of the urea plants in the world operate a prill tower; the majority are now several decades old and their capacities have increased by creep to some 120 to 130% of their original design capacity. These plants typically face several problems or challenges: high ammonia and dust emissions from the prilling tower, low prill quality, competition from granules in the market and demand from farmers for additional nutrients for their crops. The solution to all four challenges in one step is the … This paper explains how the system meets these challenges and also outlines a number of additional benefits.

This paper is the first part of totally two parts.