Abstract: This study is focused on the breakup phenomenon of urea droplet jets emerging from the rotating prilling bucket by theoretical and computational methods. Urea melt is pumped into the perforated rotating bucket having different orifice sizes from which molten urea breaks out in the form of droplets and solidifies to form of prills. The breakup of liquid jet into droplets formation in the prilling process has been analyzed. The criteria of Ohnesorge and Weber number are used to determine the regime map for the droplet formation. By increasing the rotational speed, more secondary droplet are formed which are undesired in industrial process as it causes dust formation. Liquid viscosity and exit velocity are crucial parameters for prediction of droplet size distribution. Computational Fluid Dynamics simulation is used to find a more precise velocity of urea fluid and to confirm analysis of the droplet formation.