Urea prills are produced in the prilling towers where a solidification-cooling process takes place. The ambient air is used as the cooling air stream for this process. In hot days, the temperature of the product at the bottom of the tower are hot that cannot be packed directly. In addition, in hot/ humid days, the prills form lamps and cakes with each other and on the scrubber. A mathematical model based on the hydrodynamics, heat, and mass transfer between the urea and the cooling air is developed. A numerical technique with an explicit scheme is used to solve the model. The model results describe the variation of the temperature and moisture along the radius of the particle. Hence, the model results introduce an interpretation of the problem of caking and lamps formation appears because of the incomplete solidification of the prills at the bottom of the tower. In addition, the results predict the quality of the product under different operating conditions of the ambient cooling air. Urea is marketed as a solution or in the solid form. Urea in solid form is produced in the final process stage by either granulation or prilling. Transformation of urea from melt to solid prills takes place in the urea prilling tower. In the prilling process, urea melt is pumped to the top of 50 to 60 meter (above ground) cylindrical concrete tower where it is fed to the prilling device that called rotating bucket. The rotating bucket is a sieve-like cylindrical or conical drum that rotates about its axis. Liquid jets emerge from the various holes on the curved surface of the drum, and break up due to centrifugal and capillary instability. The liquid urea droplets formed fall downward the prilling tower. A countercurrent cooling air stream enters from intake openings located around the circumference of the tower at a height approximately 7 meters from the ground level of the tower. Heat and mass transfer between the downward urea droplets and the upward cooling air stream along the height of the tower occurs, and thus a solidification-cooling process takes place. The product, urea prills, goes from the tower base to a conveyor belt where it has collected and packed. The air stream exhaust from the tower through the exhausted stakes located at the top of the tower where it spreads in the surrounding environment. As ambient air is used in the process of cooling and solidification of the prills inside the tower, thus both the dry bulb temperature and humidity of the ambient air highly affect the quality of the final product. In this study, a case study of a prilling process in Abu Qir Fertilizers Co, Alexandria, Egypt is considered. Based on the reported information from the company that is in some days in summer session, the prills are hot to the limit that cannot be packed directly. The delay in the packing process leads to a decrease in the yearly company production. In addition, in humid/ hot days, the lamp of prills forms at the bottom of the tower that also is not desired for the product quality.