Abstract:
Embodiments of the present disclosure include systems and methods of producing granulated fertilizer products. In some embodiments, the granulated fertilizer product includes a double salt of ammonium nitrate and sulfate nitrate having the formula NH 4 SO 4 .2(NH 4 NO 3 ).

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit under Title 35, U.S.C. §119(e) of U.S. Provisional Application Ser. No. 62/132,109 entitled GRANULATOR FEED APPARATUS, filed on Mar. 12, 2015, the entire disclosure of which is expressly incorporated by reference herein. 
     
    
     FIELD 
       [0002]    The present invention relates to apparatus and methods for granulators, and in particular granulators for producing fertilizer products. 
       BACKGROUND 
       [0003]    Ammonium sulfate nitrate (ASN), one of the first synthetic fertilizers, has been in continuous use for nearly 100 years providing the important primary and secondary nutrients, nitrogen and sulfur. Nitrogen is provided in part through the nitrate ion, desirable because it is readily absorbed by many plants and promotes early growth. 
         [0004]    Exemplary ASN fertilizers include double salts of ammonium nitrate and ammonium sulfate having the formula NH 4 SO 4 .2(NH 4 NO 3 ) (known as a 2:1 double salt) and NH 4 SO 4 .3(NH 4 NO 3 ) (known as a 3:1 double salt), such as disclosed in U.S. Pat. No. 6,689,181, which is incorporated herein by reference in its entirety. The term “double salt” as used herein means a chemical compound composed of ions from two precursor compounds whose crystal structure is distinct from those of the precursor compounds. The molar ratio of precursor compounds in a double salt is in the proportion of small integers, e.g., 1:2, and is not continuously variable as in a solid solution. Thus, the term “double salt of ammonium nitrate” means a combination of ammonium nitrate and another compound, such as ammonium sulfate, in such a way as to form new compound which may be crystallographically distinct from either of the constituents. Additional double salt compositions are disclose in U.S. Pat. Nos. 8,075,660, 8,721,760, and 8,814,977, the disclosures of which are incorporated herein by reference in their entirety. 
         [0005]    A double salt of ammonium nitrate and ammonium sulfate consists of small ammonium sulfate crystals imbedded in a matrix of the other constituents. A double salt is to be distinguished from a mixture of free particles. The bulk of the ammonium sulfate crystals are approximately the same size as the initial ammonium sulfate particles, but upon solidification about 5 wt. % precipitate as crystals of less than about 2 micrometer dimension. The crystals of ammonium sulfate are dispersed in the matrix in a uniform manner. The small size and uniform dispersion of the ammonium sulfate crystals in the 1:2 double salt significantly enhance the stability of the product against detonation hazard. The &#39;181 patent recognized the benefit of the 2:1 double salt as being a more stable compound. The 2:1 double salts are useful as fertilizers, have reduced moisture sensitivity, are not considered hazardous materials under Title 49 of the Code of Federal Regulations, “Transportation”, Part 172, “Hazardous Materials Table”, Oct. 1, 2000, and are not classified as oxidizers under United Nations Recommendations on the Transport of Dangerous Goods, Manual of Tests and Criteria, 1995″, “Section 34, Classification Procedures, Test Methods and Criteria Relating to Oxidizing Substances of Division 5.1”. Additional examples of methods of producing 2:1 double salts are provided in U.S. Pat. No. 8,623,315, which is also incorporated by reference herein in its entirety. 
         [0006]    ASN fertilizers are generally produced by granulation of ammonium sulfate (AS) solids with ammonium nitrate (AN) liquors. Exemplary granulation methods are disclosed in U.S. Patent Application Publication No. 2013/0192323, which is incorporated herein by reference in its entirety. Alternatively, ASN fertilizers may be processed as a melt slurry from either the constituent fertilizers (ammonium nitrate and ammonium sulfate) or, alternatively, from the reaction products of sulfuric/nitric acids with anhydrous ammonia. There are several alternatives for converting the melt slurry into solid fertilizer particles with the physical properties desired by various markets. 
         [0007]    Prilling is a process in which a liquid melt is gently streamed from the top of a tall structure with counter-current cooling air. Surface tension divides the stream into individual droplets which solidify before reaching the tower bottom. An illustrative example of prilling may be found in U.S. Pat. No. 7,175,684, which is incorporated by reference herein in its entirety. 
         [0008]    Pastillation is similar to prilling in that the melt is converted to a droplet and then solidified. However, it differs from prilling in two distinct aspects. First, rather than relying on surface tension to size the droplets, the droplets are portioned mechanically thus achieving very high uniformity in size. Second, rather than dropping the droplet through cooling air, the droplet is applied to a water-cooled metal belt. The heat is removed through the belt and solidified particles fall off the belt at its end. An illustrative example of pastillation may be found in U.S. Pat. No. 7,985,393, which is incorporated by reference herein in its entirety. 
         [0009]    In one type of granulation process, a melt slurry is sprayed onto a moving bed of granules. The melt slurry both coats and agglomerates bed granules to increase in size. In some embodiments, the granules are discharged to a dryer drum which, if included, provides additional rolling time for the granules. The granules pass to a screening operation where the product cut is recovered and the under-sized and over-sized material is recycled back to the granulation drum. 
       SUMMARY 
       [0010]    Embodiments of the present disclosure include systems and methods of producing granulated fertilizer products. In some embodiments, the granulated fertilizer product includes a double salt of ammonium nitrate and sulfate nitrate having the formula NH 4 SO 4 .2(NH 4 NO 3 ). 
         [0011]    In some embodiments, the disclosure relates to a method of producing a granulated fertilizer product. The method includes providing a melt slurry, mixing an inert fluid with the melt slurry to form a mixture, spraying the mixture in a granulation bed of a granulation drum; and solidifying the melt slurry in the granulation drum to form a granulated fertilizer product. 
         [0012]    In one more particular embodiment, the melt slurry comprises ammonium nitrate and ammonium sulfate, and wherein the product includes a double salt of ammonium nitrate and ammonium sulfate having the formula NH4SO4.2(NH4NO3). In an even more particular embodiment, at least 50 wt. % of the product consists of the NH 4 SO 4 .2(NH 4 NO 3 ) double salt. In another more particular embodiment, less than about 7 wt. % of the product consists of unreacted and underreacted ammonium nitrate and the NH 4 SO 4 .3(NH 4 NO 3 ) double salt. In still another more particular embodiment, the melt slurry comprises a molar ratio of ammonium nitrate to ammonium sulfate of about 0.9:1 to about 1.1:1. In yet still another more particular embodiment, the product comprises granules having a water content from about 0.4 wt. % to about 2.0 wt. %. Another more particular embodiment, the granulation bed is maintained at a temperature from about 80° C. to about 120° C. 
         [0013]    In another more particular embodiment of any of the above embodiments, the weight fraction of granules exiting the granulation drum retained on a +10 Tyler mesh screen is 35 wt. % or greater. In another more particular embodiment of any of the above embodiments, the granules exiting the granulation drum have a crush strength of 8 pounds per granule or greater. 
         [0014]    In another more particular embodiment of any of the above embodiments, the inert fluid is a volatile fluid, and the granulated fertilizer product does not wholly include the volatile fluid. In another more particular embodiment of any of the above embodiments, the inert fluid is selected from the group consisting of: steam, liquid water, air, nitrogen, and argon. In another more particular embodiment of any of the above embodiments, the inert fluid is steam. In another more particular embodiment of any of the above embodiments, the inert fluid is liquid water. In another more particular embodiment of any of the above embodiments, the inert fluid is compressed air. In another more particular embodiment of any of the above embodiments, the inert fluid has an atmospheric boiling point of about 110° C. or less. 
         [0015]    In another more particular embodiment of any of the above embodiments, the inert fluid is provided at an amount, based on the weight of the melt slurry, of from about 0.01 wt. % to ratio to about 20 wt. %. In another more particular embodiment of any of the above embodiments, the inert fluid is provided at an amount, based on the weight of the melt slurry, of from about 0.01 wt. % to ratio to about 0.03 wt. %. In another more particular embodiment of any of the above embodiments, the inert fluid is provided at an amount, based on the weight of the melt slurry, of from about 4 wt. % to ratio to about 20 wt. %. 
         [0016]    In another more particular embodiment of any of the above embodiments, the method further includes measuring at least one property of the melt slurry with at least one instrument, wherein said mixing step is performed after said measuring step. In another even more particular embodiment, said measuring includes measuring at least one property selected from the group consisting of flow rate, pressure, and temperature. 
         [0017]    In another more particular embodiment of any of the above embodiments, said mixing is performed by injecting the inert fluid into the melt slurry at an injection location in a conduit of the granulation drum. In an even more particular embodiment, the injection location is a header or a distributor of the granulation drum. 
         [0018]    In another more particular embodiment of any of the above embodiments, said mixing is performed by injecting the inert fluid into the melt slurry at an injection location in a conduit prior to entering the granulation drum. In another more particular embodiment of any of the above embodiments, the injection point is positioned proximate a coupling between the conduit and the granulation drum. 
         [0019]    The above mentioned and other features of the invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]      FIG. 1  is a schematic illustration of an exemplary granulation process. 
           [0021]      FIG. 2  is a cross-section of a granulation drum useful in an embodiment of the granulation process of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION 
       [0022]    Although the embodiments discussed below pertain primarily to solid ASN materials, similar techniques could be applied to other granulation products, including, without limitation, ammonium nitrate, ammonium sulfate, and urea products. In addition, although the embodiments discussed below pertain primarily to materials produced by continuous granulation processes, similar techniques could be applied to prilling or pastillation processes. As used herein, the term “solidification device” encompasses any type of device in which a melt slurry may be solidified, with non-limiting examples of solidification devices including granulation devices, prilling devices, and pastillation devices. 
         [0023]      FIG. 1  provides a schematic view of an illustrative but non-limiting embodiment of a granulation system  10 . As illustrated, the granulation system  10  includes a granulation drum  12 . Melt slurry is provided from a feed preparation vessel  14  though a pump  16  through conduit  22 . In one embodiment, granulation system  10  may further include one or more of a dryer/cooler drum, a screener, and a crusher (not shown). In one embodiment, the granulation system is configured as a loop in order to recycle off-specification (i.e., oversized and/or undersized) material back to the granulation drum  12  until it is brought into target specifications. It will be appreciated that granulation configurations can include a variety of different equipment types, configurations, sizes and operating parameters. 
         [0024]    In some embodiments, the melt slurry is formed by combining particles of ammonium nitrate and ammonium sulfate in the presence of a small amount of water, and heating to a temperature sufficient to melt the ammonium nitrate and mixing thoroughly to disperse the solid ammonium sulfate. In some embodiments, the melt slurry comprises a molar ratio of ammonium nitrate to ammonium sulfate of about 0.9:1 to about 1.1:1. The particle size of the ammonium nitrate is not critical but in some embodiments, about 95 wt. % of the ammonium nitrate particles pass a Tyler No. 6 sieve (3.36 mm opening). With respect to the ammonium sulfate, the smaller the particle, the more rapid the reaction between the ammonium sulfate and ammonium nitrate and the finer will be the scale of their dispersion. In some embodiments, the ammonium sulfate is at least about 85 wt. % passable through a Tyler No. 48 sieve (0.30 mm opening). Ammonium sulfate subjected to commercial ball milling typically meets this criterion without additional screening. In some embodiments, the ammonium sulfate is about 99 wt. % passable through a Tyler No. 48 sieve. In other embodiments, the ammonium sulfate is about 99 wt. % passable through a Tyler No. 48 sieve and about 50 wt. % passable through a Tyler No. 200 sieve (0.074 mm opening). 
         [0025]    The properties of the melt slurry in conduit  22  may be monitored by one or more sensing and control instruments. Exemplary instruments include pressure and/or temperature instruments  44 , and flow element  46 . An exemplary flow element includes a Coriolis-type flow meter. Flow element  46  may be operatively coupled to a controller  48 . Controller  48  is operatively coupled to a valve  50  controlling the flow rate of melt slurry through conduit  22 . 
         [0026]    In one embodiment, the granulation drum  12  is operated to produce granules having a water content of as low as about 0.4 wt. %, as low as about 0.5 wt. %, or as low as about 0.6 wt. % and as high as about 1.5 wt. %, as high as about 1.75 wt. %, or as high as about 2.0 wt. %. In other embodiments, the resulting solid ASN composition has a water content that is within any range defined between any pair of the foregoing values, such as about 0.4 wt. % to about 2.0 wt. %, about 0.5 wt. % to about 1.75 wt. %, or about 0.5 wt. % to about 1.5 wt. %. In some embodiments, the granule bed is maintained at a temperature as low as about 80° C., as low as about 85°, as low as about 90° C., or as low as about 95° C. and as high as about 100° C., as high as about 105° C., as high as about 110° C. or as high as about 120° C. In other embodiments, the granule bed is maintained at a temperature that is within any range defined between any pair of the foregoing values, such as about 80° C. to about 120° C., about 85° C. to about 110° C., or about 90° C. to about 100° C. These temperatures are significantly below the melting temperature of the ASN material. In some embodiments, the temperature of the granulation bed is determined using a temperature sensing probe having an active element submerged in the moving solids. In contrast, conventional granulation processes operate at a bed temperature of 140-160° C., which is much closer to the melting temperature of the ASN material resulting in production of granules with a water content generally below 0.4 wt.%. 
         [0027]    In one exemplary embodiment, the weight fraction of granules exiting the granulation drum  12  retained on a +10 Tyler mesh screen is as little as 35 wt. %, 40 wt. %, 50 wt. %, as great as 55 wt. %, 60 wt. %, 65 wt. %, 70 wt. %, or greater, or within any range defined between any two of the foregoing values, such as 35 wt. % or greater, 50 wt. % or greater, or 40 wt. % to 70 wt. %. 
         [0028]    In one exemplary embodiment, the granules exiting the granulation drum  12  have a crush strength as little as 5 pounds per granule, 6 pounds per granule, 7 pounds per granule, as great as 8 pounds per granule, 10 pounds per granule, 15 pounds per granule, or higher, or within any range defined between any two of the foregoing values, such as 5 pounds per granule or greater, 8 pounds per granule or greater, 6 pounds per granule to 15 pounds per granule, or 8 pounds per granule to 15 pounds per granule. 
         [0029]      FIG. 2  is a cross-sectional view of the granulation drum  12 , taken along line  2 - 2  of  FIG. 1 , illustrating internal components of the granulation drum  12 . In the illustrated orientation, the granulation drum  12  rotates in a direction indicated by an arrow  31 . The granulation drum  12  has an inner surface  32  and contains a quantity of granules  34 . 
         [0030]    The granulation drum  12  includes one or more melt slurry spray nozzles  36  that are arranged and configured to spray the granules  34  with fresh melt slurry from inlet conduit  26 . While a single melt slurry spray nozzle  36  is illustrated in  FIG. 2 , it will be appreciated that in some embodiments a plurality of nozzles  36  may be used. 
         [0031]    A bank  38  of spray nozzles, in addition to the melt slurry nozzles  36 , may, as illustrated, include one or more solution spray nozzles  40  that may be configured to spray liquid water or fertilizer solution recycled or recovered from other plant operations, as desired, onto the granules  34 . In some embodiments, additional ammonia can be added to adjust the pH either by adding ammonia alone or in combination with one or more of water of fertilizer solution. In some embodiments, the bank  38  includes one or more steam injection nozzles  42  that may be configured to inject steam into the granulation drum  12 . To account for the cooling duty to solidify the melt-slurry, embodiments of the present invention control the water, air and steam that is sprayed/injected onto the granule bed to control the moisture content while still maintaining desirable physical properties of the resulting ASN material including crush strength. In another embodiment, additional ammonia is added to the granulation drum  12 , either through the spray bank  38  or in any other acceptable manner. In some embodiments, additional ammonia is added in order to adjust the pH upwards towards the product pH such that the pH at the moment of discharge from the granulation bed is substantially the same as the normal product pH. As further set forth in the Examples, the ammonia raises the pH of the solid ASN material, which may facilitate the more rapid and complete conversion of the ammonium sulfate nitrate 3:1 double salt to the ammonium sulfate nitrate 2:1 double salt. 
         [0032]    Referring again to  FIG. 1 , in one exemplary embodiment, an air source  54  provides temperature and/or humidity controlled air at a desired flow rate via an air inlet  56  in order to selectively modify a rate of air flow through the granulation bed. Air is vented from the granulation drum  12  via a vent  28 . An outlet  30  transports product from the granulation drum  12 . In some exemplary embodiments, granulation drum  12  may further include an inlet  58  for product recycle, and a rolling seed bed in the interior of the granulation drum  12 . 
         [0033]    In some embodiments, less than about 7 wt. % of the product consists of the unreacted and underreacted ammonium nitrate or 1:3 double salt species. In some embodiments, less than about 5 wt. % or even less than about 3 wt. % of the product consists of the unreacted and underreacted ammonium nitrate or 1:3 double salt species. In one embodiment, water content is controlled such that the resulting solid ASN composition has a water content of as low as about 0.4 wt. %, as low as about 0.5 wt. %, or as low as 0.6 wt. % and as high as about 1.5 wt. %, as high as about 1.75 wt. %, or as high as about 2.0 wt. %. In other embodiments, the resulting solid ASN composition has a water content that is within any range defined between any pair of the foregoing values, such as such as about 0.4 wt. % to about 2.0 wt. %, about 0.5 wt. % to about 1.75 wt. %, or about 0.5 wt. % to about 1.5 wt. %. By controlling the water content within these ranges, ASN 2:1 double salt conversion is maximized while still maintaining the structural integrity (e.g., crush strength) of the resulting material. As used herein, water content refers to the average water content of a sample of solid ASN material, as determined via conventional gravimetric analysis, taken during or shortly after production as indicated. 
         [0034]    As illustrated in  FIG. 1 , an inert fluid is provided from a fluid source  18 . The inert fluid is illustratively added to the melt slurry at injection point  20 A or injection point  20 B. Injection point  20 A is illustratively a portion of the header  24  or distributor of inlet conduit of granulator drum  12 . Injection point  20 B is illustratively a portion of conduit  22  positioned upstream of the header  24  or distributor. In one exemplary embodiment, the injection point  20 A is an open penetration and block valve into header  24 . In one exemplary embodiment, the injection point  20 B is an open penetration and block valve into conduit  22 . In some exemplary embodiments, injection point  20  may further comprise one or more baffles (not shown) for promoting additional mixing between the melt slurry and the inert fluid. A valve  52  is illustratively positioned between fluid source  18  and injection point  20  to control flow of the inert fluid into injection point  20 . 
         [0035]    As illustrated in  FIG. 1 , injection points  20 A and  20 B are illustratively positioned downstream of sensing and control instruments, such as pressure and/or temperature instruments  44 , and flow element  46 . In some embodiments, the injection of inert fluid into conduit  22  upstream of the sensing and control instruments may disrupt the measurement capability and/or physically harm one or more of the instruments. 
         [0036]    As used herein, the term inert fluid refers to a secondary medium that is chemically inert with respect to the primary melt fluid in conduit  22 , which primarily modifies the physical spray characteristics as it co-discharges from the plurality of nozzles  36  of the melt slurry in granulator  12 . In one embodiment, the inert fluid is not wholly incorporated into the final granulated product, and can be reasonably expected to separate from the granulated product by remaining in a vapor state upon solidification of primary melt feed, or alternatively by evaporating at the granule bed temperature conditions to the same equilibrium condition. In some exemplary embodiments, the inert fluid is a volatile fluid having an atmospheric boiling point of about 110° C. or less. Without wishing to be held to any theory, it is believed that the inclusion of the volatile fluid produces a mixed phase droplet suspension, which increases the relative velocity of the melt slurry on exiting the nozzles  36 . In one exemplary embodiment, the inert fluid is selected from the group consisting of steam, liquid water, compressed air, and inert gases such as nitrogen and argon. 
         [0037]    In one exemplary embodiment, the inert fluid is steam. Without wishing to be held to any particular theory, at relatively low levels, it is believed that the steam will minimally compete with melt for available flow area within nozzles  36 , yielding no appreciable effect. At moderate levels, the steam will increase pressure observed in conduit  26  and increase velocity of both fluids exiting nozzles  36 , yielding an increased spread in spray pattern without a cooling effect. At relatively high levels, the steam will increase pressure observed in conduit  26  and increase velocity of both fluids exiting nozzles  36 , yielding an erratic spread pattern without a cooling effect, and potentially preventing desired control of melt flow via valve  50 . 
         [0038]    In one exemplary embodiment, the inert fluid is liquid water. Without wishing to be held to any particular theory, at relatively low levels, it is believed that at relatively low levels, the liquid water will substantially vaporize to steam, increasing pressure and decreasing temperature observed in conduit  26  and increasing velocity of both fluids exiting nozzles  36 , yielding an increased spread in spray pattern with a cooling effect. At moderate levels, the liquid water will partially vaporize to steam, increasing pressure and decreasing temperature observed in conduit  26  and increasing velocity of both fluids exiting nozzles  36 , yielding an increased spread in spray pattern with a cooling effect. At relatively high levels, the liquid water will partially vaporize to steam, increasing pressure and decreasing temperature observed in conduit  26  while substantially diluting the melt feed. Increased velocity of both fluids exiting nozzles  36  are exhibited with a decrease in viscosity, yielding an increased spread in spray pattern with significant cooling effect. In one exemplary embodiment where the inert fluid is liquid water, a relatively low level of inert fluid is below about 4 wt. % based on the weight of the melt slurry, a moderate level of inert fluid is about 4 wt. % to about 15 wt. % based on the weight of the melt slurry, and a relatively high level of inert fluid is greater than about 4 wt. %, based on the weight of the melt slurry. 
         [0039]    In one exemplary embodiment, the inert fluid is a compressed gas, such as compressed air, compressed nitrogen, or compressed argon. Without wishing to be held to any particular theory, at relatively low levels, it is believed that at relatively low levels, the compressed gas will minimally compete with melt for available flow area within nozzles  36 , yielding no appreciable effect. At moderate levels, the compressed gas will increase pressure observed in conduit  26  and increase velocity of both fluids exiting nozzles  36 , yielding an increased spread in spray pattern with a cooling effect. At relatively high levels, the compressed gas will increase pressure observed in conduit  26  and increase velocity of both fluids exiting nozzles  36 , yielding an erratic spread pattern with a significant cooling effect, and potentially preventing desired control of melt flow via valve  50 . 
         [0040]    In some exemplary embodiments, the amount of inert fluid, based on the weight of melt slurry, is as little as 0.01 wt. %, 0.02 wt. %, 0.03 wt. %, as great as 4 wt. %, 6 wt. %, 13 wt. %, 15 wt. %, 20 wt. %, or within any range defined between any two of the foregoing values, such as 0.01 wt. % to 20 wt. %, 0.01 wt. % to 0.03 wt. %, 0.02 wt. % to 13 wt. %, 0.03 wt. % to 4 wt. %, 4 wt. % to 15 wt. %, 4 wt. % to 13 wt. %, or 4 wt. % to 20 wt. %. 
         [0041]    As used herein, the term additive refers to a chemical modifier of the melt slurry or final product. Additives, which are typically non-volatile and wholly incorporated into the final product, are not included in the group of inert fluids. Exemplary additives include granulation aids, such as aluminum sulfate, calcium or magnesium compounds, iron sulfate, zinc salts, or many proprietary additive blends including but not limited to binder, hardening, and spreading agents. Fluids added specifically to control product pH or storage properties are also not included in the group of inert fluids. 
         [0042]    In one exemplary embodiment, the injection of the inert fluid into the conduit  22  and/or header  24  of inlet conduit  26  provides synergistic results compared to a similar injection of melt slurry and a separate injection of the inert fluid through a separate inlet into granulation drum  12 . 
       Examples 
       [0043]    In one exemplary embodiment, the injection of liquid water into the header  24  of inlet conduit  26  provides synergistic results compared to a similar injection of melt slurry and a separate injection of liquid water through a separate inlet  40  into granulation drum  12 . In this example, the primary melt feed is equimolar ammonium sulfate nitrate slurry at approximately 180° C., which is pre-saturated with water at atmospheric pressure of approximately 4-5 wt. %. Injection of secondary fluid liquid water into header  24  is maintained in a range of 4%-15% by weight of primary melt feed. 
         [0044]    Without the injection of the secondary fluid liquid water, the granules exiting granulation drum  12  were typically undersized, and granulation drum  12  did not achieve sustained steady state of particle size fractions, necessitating shutdown of the unit. The weight fraction of granules exiting the granulation drum  12  retained on a +10 Tyler mesh screen was less than about 30%. In addition, the crush strength of the resulting granules was typically less than about 5 pounds per granule. 
         [0045]    In contrast, with the injection of the 4-15 wt. % of secondary fluid, the granulation drum  12  was successfully operated at steady state on a continuous basis, and the weight fraction of granules retained on a +10 Tyler mesh screen was greater than about 60%. Additionally, the crush strength of the resulting granules was typically greater than 8 pounds per granule, to as high as 15 pounds per granule. 
         [0046]    Without wishing to be held to any particular theory, it is believed that the injected water performs three discrete functions to modify the spray behavior: primarily, a small portion of the injected secondary fluid, &lt;1%, is vaporized to steam providing a desired increase in melt spray pattern. Secondarily, the injected water temporarily associates with the melt to an extent not achievable without increased feed preparation pressure. Thirdly, the injected water provides a high level of targeted evaporative cooling that improves granule bed temperature control and elimination of localized hot spots. This synergistic effect results in an observed decrease in undersized fine particles (&lt;0.5 mm) that were not successfully incorporated into a larger, target size granule of 2-3.5 mm. In both cases, where liquid water is injected in the targeted range of 4-13 wt. % via nozzle  40  or inlet  20 , product granules exiting the granulator device exhibit moisture levels less than about 2.0 wt. %, and more preferably less than about 1.5 wt. %, which is less than the primary feed composition (4-5 wt. %), indicating that no additional water was incorporated into the granule across this process. 
         [0047]    While this invention has been described as relative to exemplary designs, the present invention may be further modified within the spirit and scope of this disclosure. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.