Separation of Exhaust Gas Pollutants from Urea Prilling Process with Gasified Biochar for Slow-Release Fertilizer: Adsorption Characteristics, Process Improvement, and Economic Assessment

To address severe ammonia gas and dust pollution coupled with resource waste in exhaust gases from urea prilling towers, a production process for gasified biochar-based slow-release fertilizer is proposed to achieve resource recovery of exhaust pollutants. Through phosphoric acid impregnation modification applied to gasified biochar, its ammonia gas adsorption capacity was significantly enhanced, with saturated adsorption capacity increasing from 0.61 mg/g (unmodified) to 32 mg/g. Coupled with the tower-top bag filter, the modified biochar combines with ammonia gas and urea dust in exhaust gases, subsequently forming biochar-based slow-release fertilizer through dehydration and granulation processes. Material balance analysis demonstrates that a single 400,000-ton/year urea prilling tower achieves a daily fertilizer production capacity of 55 tons, with 18% active ingredient content. The nitrogen content can be upgraded to national standards through urea supplementation. Economic analysis demonstrates a total capital investment of USD1.2 million, with an annual net profit of USD0.88 million and a static payback period of 1.36 years. This process not only achieves ammonia gas emission reduction but also converts waste biochar into high-value fertilizer. It displays dual advantages of environmental benefits and economic feasibility and provides an innovative solution for resource utilization of the exhaust gases from the urea prilling process.