High-Efficiency Salt Drying Using Shaking Fluid Bed Dryer – 20 TPH System Design & Technical Analysis

1. Introduction

Salt stands as one of the most ubiquitously utilized industrial materials and food additives across the globe, playing an indispensable role in numerous manufacturing processes and daily dietary needs. In contemporary salt processing facilities, the imperative of maintaining stable, energy-efficient drying operations with rigorous moisture control has emerged as a cornerstone for upholding both product quality and production efficiency. This critical requirement stems from the need to ensure consistent material properties, prevent caking or degradation, and optimize energy utilization in large-scale industrial settings.

This article delves into the detailed design and technical configuration of a Shaking Fluid Bed Dryer system specifically tailored to handle 20 tons per hour (TPH) of salt. The process involves reducing the initial moisture content from 5% to 1a stringent final level of ≤0.2%, leveraging an inlet air temperature regulated around 250°C to facilitate efficient evaporation. The fluid bed drying system is engineered to ensure the outlet product temperature remains at 100°C, striking a balance between drying efficiency and material stability. By exploring the mechanical specifications, thermal management strategies, and operational parameters, this analysis aims to shed light on how such systems can effectively meet the demanding requirements of high-volume salt drying with optimal energy performance.

2. Technological Transition in Shaking Fluid Bed Dryers

Historically, shaking fluid bed dryers manufactured by renowned European enterprises have been synonymous with cutting-edge drying technology, finding extensive applications across diverse industries. However, Chinese companies led by Hywell Machinery have recently emerged as key players in this domain, producing comparable systems that embody compact engineering, low energy consumption, and superior fluidization performance.

These fluidized drying systems feature unparalleled control over critical drying parameters, enabled by advanced fluidization mechanisms that ensure uniform heat and mass transfer. This makes them ideally suited for applications requiring precise moisture reduction, including salt drying, soda ash processing, fertilizer production, and crystalline material treatment. By maintaining stable operational conditions while minimizing energy waste, they have become the preferred choice in modern industrial drying—marking a significant shift in the global technology landscape.

3. Technical Requirements for 20Ton per Hour Salt Drying

To define a suitable drying solution for salt, the following process parameters are considered:

• Material: Crystalline Salt (e.g.,      NaCl, purified salt)

• Throughput: 20 tons/hour

• Initial Moisture: 5% (wet basis)

• Final Moisture: ≤0.2%

• Inlet Air Temperature: Approx.      250°C

• Outlet Product Temperature: ≤100°C

• Drying Objective: Continuous,      stable drying without integrated cooling

• Process Control: Precise temperature      and residence time regulation

• Energy Efficiency: Reduced air      volume and minimal heat loss

Moisture to be removed:
5% of 20,000 kg = 1,000 kg water/hour

Latent heat required (approx.):
1,000 kg × 540 kcal/kg = 540,000 kcal/hour

Considering system losses (20–30%), the required thermal input becomes approximately:
900,000 to 1,200,000 kcal/hour

4. Shaking fluid bed dryer to drying salt video 

5. Recommended Equipment: Shaking Fluid Bed Dryer (Hywell Design)

Case studies and practical experience with HYWELL shaking fluid bed dryers indicate that a system configured with a 9m × 2m drying deck (offering 18 m² of effective drying area) demonstrates consistent capability to dry up to 20 tons of salt per hour without requiring a cooling section.

1. Proposed Dryer Specification:

Parameter	Value
Dryer Type	Shaking Fluid Bed Dryer (Drying only)
Manufacturer	HYWELL Process or equivalent
Effective Bed Area	~18 m² (6.0m × 3.0m)
Number of Units	1 unit
Operating Temperature	Inlet: 250°C / Outlet: 100°C
Airflow	~35,000 – 38,000 Nm³/h
Blower Power	~95–125 kW
Thermal Energy Requirement	900,000–1,200,000 kcal/h
Residence Time	15–20 minutes
Shaking Frequency	2–4 Hz (depending on design)
Note: If a cooling section is needed   (e.g., product temperature ≤ 40°C), an additional 3 meters of cooling deck   would be added.

6. Process Flow Description

1. Consistent Feeding System for Uniform Continuous fluidized bed drying

Wet salt enters the dryer via a feed system with a screw conveyor or rotary valve, ensuring consistent material flow for uniform drying. The screw conveyor uses a helical blade to prevent segregation, while the rotary valve regulates feed rates with minimal air leakage.

2. High-Efficiency Hot Air Supply at 250°C

Hot air at 250°C is supplied by a high-efficiency blower from a gas-fired or steam heat exchanger. Gas-fired units offer rapid temperature response, and steam systems provide precise control. The blower maintains airflow velocity for optimal fluidization of salt particles.

3. Dual Drying Action: Fluidization and Shaking

Inside the dryer, salt undergoes dual action: fluidization by upward hot air and forward movement via bed shaking. This ensures uniform particle exposure to hot air, maximizing heat transfer. The shaking mechanism, driven by eccentric weights, prevents particle damage, while fluidization eliminates drying dead zones.

4. Precise Moisture Evaporation and Temperature Control

Moisture evaporates efficiently due to high air-solid contact and precise temperature control. An air distribution plate ensures uniform airflow, and temperature sensors adjust inlet air to maintain conditions, reducing moisture from 5% to ≤0.2%.

5. Efficient Product Discharge at Controlled Temperature

Dried salt (≤0.2% moisture) exits at 90–100°C, with a discharge mechanism preventing backflow. Outlet temperature balances energy efficiency and safe downstream processing.

6. Exhaust Air Filtration and Energy Recovery

Exhaust air is filtered or routed to an energy recovery system. Filtration meets emissions standards, while heat exchangers reuse thermal energy, reducing energy consumption and enhancing sustainability.

7. Thermal Load and Blower Design

To evaporate 1,000 kg/h of water, the system must manage significant airflow and thermal input:

1. Heat Load Calculation:

• Latent Heat of water: ~540 kcal/kg

• Required Evaporation: 1,000 kg/h

• Theoretical Heat Demand: 540,000      kcal/h

• With 25% losses: ~720,000 kcal/h –      1,000,000 kcal/h total required

2. Blower Requirements:

• Air Volume: 35,000 – 38,000 Nm³/h

• Pressure Drop Across Bed: ~5–7 kPa

• Motor Power: 12–15 kW per unit

• Air Distribution: Controlled via      inlet plenum and damper system for uniform fluidization

8. Advantages of Shaking Fluid Bed Dryer over Vibrating Fluid Bed Dryer

Feature	Shaking Fluid Bed	Vibrating Fluid Bed
Energy Efficiency	High (lower air volume)	Medium
Air Volume Required	Low	High
Maintenance	Low (no complex vibration system)	Higher
Mechanical Simplicity	Yes	Requires spring-damper system
Noise & Vibration	Low	High
Footprint	Compact	Often longer
Suitability for Salt	Excellent	Good, but higher energy cost
The shaking mechanism enables precise forward motion of salt while   maintaining fluidization with lower air velocity, which translates to significant   energy savings. These systems are especially well-suited for dense   granular materials like salt, soda ash, or fertilizer crystals.

9. Optional Upgrades

Depending on project scale and environmental considerations, the system can include:

• Waste heat recovery units to      preheat inlet air

• Bag filter or cyclone separator for      dust removal

• Frequency-controlled blower for      process optimization

• PLC + SCADA control system for      automation

• SS316 contact parts for      food/pharma-grade processing

10. Installation & Operational Considerations

• Foundation: Rigid and level,      capable of absorbing dynamic loads

• Commissioning Time: ~3–4 weeks      including testing

• Operator Training: Typically 2–3      days

• Maintenance Cycle: Every 6 months      for inspection, annual overhaul

• Utilities: Compressed air for      actuator, fuel/gas for hot air generator, electric power for blower and      control

11. Conclusion

The Shaking Fluid Bed Dryer presents a remarkably efficient and dependable solution for industrial salt drying operations at a processing capacity of 20 TPH, effectively reducing moisture content from 5% to ≤0.2%. Engineered with a compact footprint and low energy consumption profile, this system optimizes both floor space and operational costs in modern manufacturing facilities. When compared to traditional vibrating fluid bed dryers, the shaking mechanism offers distinct advantages: enhanced energy efficiency through optimized airflow dynamics, reduced operating expenses due to minimized maintenance requirements, and smoother material transport that prevents particle degradation or segregation.

Notably, a single dryer unit featuring an 18 m² bed area is sufficient to meet the most stringent drying performance benchmarks, demonstrating its design efficiency and scalability. This configuration eliminates the need for multiple units, streamlining installation and reducing capital expenditure while maintaining consistent drying precision. For salt processing operations seeking to balance high-volume production with energy conservation and cost-effectiveness, the Shaking Fluid Bed Dryer emerges as a strategic investment that aligns with contemporary industry standards for sustainability and operational excellence.