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home/Knowledge Base/Process/Granulation/Granulation using tank-
type neutralisers and pipe-type reactors
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Granulation using tank-type

neutralisers and pipe-type reactors
910 views 0 February 21, 2020 Updated on August 15, 2022

1. Tank-type neutralisers
2. Pipe-type reactors

Tank-type neutralisers
The use of an atmospheric or pressurized tank-type neutraliser offers
maximum flexibility in managing the acid/ammonia reactions and
obtaining the critical heat/liquid phase criteria needed for
good granulation when producing a wide variety of granular NPK grades.
Because the acid/ ammonia reactions are most often only partially
completed in these tank-type neutralisers, they are often referred to as
“preneutralisers.” Such preneutralisers are commonly used in most of
today’s ammonium phosphate plants and in many NPK plants.

When a preneutraliser is used, large amounts of acid can be partially

reacted with ammonia. The degree of reaction performed in the
preneutralizer is determined by a number of factors; however, the most
important criterion is the production of a fluid slurry that is easy to
transport (pump) to the granulator and uniformly distribute onto the
rolling bed of material in the granulator.

The fluidity of the preneutralized slurry is maintained through careful

control of the NH 3:H3PO4 mole ratio (Figure 1), temperature, and free water
content of the reacted slurry. The neutralization reactions that are only
partially completed in the preneutralizer are completed in the granulator
where additional ammonia is added beneath the rolling bed of material. In
some cases, phosphoric acid may be added to the granulator to adjust the
NH3:H3PO4 mole ratio to achieve optimum granulation.
When sulphuric acid is reacted in combination with phosphoric acid in the
preneutralizer, special precautions must be taken to select construction
materials that will resist the more corrosive environment caused by the
presence of sulphuric acid. Type 316L stainless steel (SS) is not a suitable
construction material if sulphuric acid is neutralized in combination with
phosphoric acid, a more noble alloy is required. The selection of
construction materials for the preneutralizer system should be made only
after careful testing of possible construction materials under actual
operating conditions. Also, at the higher mole ratio and pH when sulphuric
acid is present (for example, about 1.5 and 6.8, respectively), the
presence of ammonium sulphate crystals tends to thicken the slurry and
make pumping difficult; thus, operation at a lower NH 3:H3PO4 mole ratio
and pH (about 0.4 and 2.0, respectively) is often preferred, when sulphuric
acid is fed to the preneutralizer.

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Pipe-type reactors

In the early 1970s, the Tennessee Valley Authority (TVA) demonstrated the
feasibility of replacing a conventional tank-type preneutralizer with a novel
device referred to as a pipe or “tee” reactor (Salladay and Paulson, 1984).
This type of reactor was a radical departure from the conventional tank-
type preneutralizer normally used to react large amounts of ammonia with
phosphoric acid. The pipe reactor consists basically of a length of
corrosion-resistant pipe (about 5·- 15 m long) to which phosphoric acid,
ammonia, and often water are simultaneously added to one end through a
piping configuration resembling a tee, thus the name “tee reactor.” The
acid and ammonia react quite violently, pressurizing the unit and causing
the superheated mixture of ammonium phosphate slurry (“melt”) and
water vapour to forcefully discharge from the opposite end of the pipe that
is positioned inside the granulator . Uniform distribution of the “melt” on
top of the rolling bed of material in the granulator is achieved by varying
the configuration and orientation of the discharge opening(s) of the pipe. A
primary advantage of the pipe reactor over conventional preneutralizers is
that the preneutralized slurry pump and piping system is eliminated and a
much more concentrated slurry can be delivered directly to the granulator.
Thus the chemical heat of reaction is more effectively used to evaporate
unwanted water from the process compared with the operation of a
conventional preneutralizer. The tee reactor was modified by TVA to also
accept an additional flow of sulphuric acid through another pipe inlet
located opposite the phosphoric acid inlet, giving the unit a “cross”
configuration and thus the name “pipe-cross reactor” (PCR) (Green [Link].,
1978; Salladay et al.,1985).

Use of the PCR makes it possible to react a wide variety of

phosphoric/sulphuric acid mixtures with ammonia. This capability is
particularly useful in NPK granulation plants and allows a greater choice in
the selection of raw materials to improve granulation and optimize the
overall cost of production. In addition, the problem of ammonium chloride
fumes is eliminated because the sulfuric acid does not come in direct-
contact with the Muriate of Potash (MOP) that may be in the formulation.

In general, the mixture discharged from the PCR does not require further
reaction with ammonia in the granulator. ln some cases, however, the
level of reaction in the PCR may be altered (decreased) to minimize the
escape of ammonia or to obtain improved granulation characteristics of
the “melt” when it is combined with the solids in the granulator.

Several variations of pipe-type reactors (and materials of construction) are

currently used in NPK, DAP, and MAP plants; sometimes the pipe-type
reactor is used in combination with a conventional tank-type
preneutralizer. Perhaps one of the greatest advantages offered by the use
of pipe reactor technology in the NPK industry is that it provides an
opportunity to effectively use a greater variety of raw materials including,
for example, larger quantities of dilute acids and scrubber liquor. This
added flexibility in raw material choices can often result in more
favourable production costs and at the same time provide a method for
disposing of certain problem materials such as excess scrubber liquor. It
should be noted, however, that the technology does not fit all situations
equally well. Therefore, its potential should be carefully examined with
regard to the particular circumstances.

References
Green, H,D.J., Brunner, R., Britt, O. and Super, A.P. (1978). Panel
discussion: Recent pipe cross experiences. In Proceedings of the 28th
Annual Meeting Fertilizer Industry Round Table, pp. 46-54, Atlanta, GA,
U.S.A.

Salladay, D.G., and Paulson, W.H. (1984). Development of IVA pressure

reactor for production of ammonium phosphates and its retrofit in
conventional plants. 34th Annual Meeting of the Fertilizer Industry Round
Table, October 30 -November 1, 1984.

Salladay, D.G., Traweek, M. S. and Louizos, N.H. (1985). Production of

monoammonium phosphate sulfate with TVA Pressure Pipe-Cross Reactor.
In Proceedings of the 35th Annual Meeting Fertilizer Industry Round Table,
pp. 102-113, Atlanta, GA, [Link]

Links to related IFS Proceedings

244, (1986), Adapting a Pipe Reactor to a Blunger for NPK Production ,

R J Milborne, D W Philip.

Links to external resources

IFDC , Fertilizer Manual

Ivell, D.M. and Ward, N.D. (1984). ‘The Use of a Pressure Neutraliser for
Slurry Granulation,’ IFA Technical Conference, Paris, France, 5-8
November.

Leyshon, D.W., Day, D. (1989). ‘MAP Manufacture Using the Pipe Reactor,’
1989 Joint Meeting Central Florida and Peninsular Florida Sections of the
AIChE, Clearwater Beach, Florida.

Mangat, I.S. and Toral, J.L. (1978). ‘Pipe Reactor – An Innovation for
Improvement of Granulation Plant,’ ISMA Technical Conference, Orlando,
Florida, USA, 23-27 October.

Moraillon, P. and Cotonea, Y. (1982). ‘Savings on Energy in Granulation of

Fertilisers by a New Method of Using Pipe Reactors,’ IFA Technical
Conference, Kallithea, Greece, 5-7 October.

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