ISSN print edition: 0366-6352 ISSN electronic edition: 1336-9075 Registr. No.: MK SR 9/7 Published monthly

Comparative analysis of physical and thermal properties of prilled and granulated urea

Samira Zafarnak, Jaspreet Sandhu, and Nejat Rahmanian

School of Chemical, Petroleum and Gas Engineering, Shiraz University, Shiraz, Iran

E-mail: n.rahmanian@bradford.ac.uk

Received: 7 June 2025  Accepted: 13 December 2025

Abstract:

Solid urea is the largest nitrogen fertilizer product, produced in two forms: granules and prills. Although the chemical properties of both prills and granules remain similar, their differing physical and mechanical properties distinguish them, making them suitable for different applications, either as fertilizers or raw materials for the chemical industry. This research aims to understand the differences between prilled and granulated urea by comparing their physical and thermal properties. The characterizations were conducted using thermal gravimetric analysis, differential scanning calorimety, Karl-Fischer titration, Scanning Electron Microscopy, High-Performance Liquid Chromatography, sieve analysis, strength measurements, and pycnometer. Karl Fischer titration revealed that granules contain more moisture (0.48%) compared to prills (0.34%). The moisture content of a fertilizer during storage and handling affects its overall quality. HPLC analysis on biuret content showed that the prilled samples contained higher biuret content. The results of the sieve analysis technique used to determine the size distribution indicated that granules had a larger mean diameter of 2.81 mm compared to prills, which had a mean diameter of 1.64 mm. SEM images revealed clear differences in terms of shape and structure between the prills and granules. The outer surface of the prills was smoother and glass-like, while the granules appeared rougher. Interestingly, on the inside, the granules had a denser and more solid middle layer. In contrast, the prills exhibited cracks throughout their inner structure.

Keywords: Urea fertilizer; Granulation; Prilling process; Agricultural application; Thermal properties

Full paper is available at www.springerlink.com.

DOI: 10.1007/s11696-025-04601-8

Chemical Papers 80 (5) 4945–4960 (2026)