50,000 TPY Industrial Salt & Deicing Agent Double Roller Extrusion Line

1. Project Background & Client Challenges

As winter road maintenance standards become more stringent across North America and Europe, traditional fine industrial salt and raw mineral powders face severe commercial limitations. Loose fine salt suffers from heavy moisture absorption, warehouse caking, high shipping dust losses, and uneven spreading by modern municipal deicing trucks.

An international chemical and mineral processing enterprise sought to build a state-of-the-art Deicing Agent & Industrial Salt Granulation Plant to supply high-density, free-flowing deicing pellets (2.0--6.0 mm) to overseas municipal highway authorities.

Key Client Requirements:

1. Zero Thermal Drying (Energy Cost Control): Wet granulation requires massive fuel consumption and generates hot, highly corrosive salt vapor. A 100% dry compaction process was mandatory.

2. Heavy-Duty Anti-Corrosion Engineering: Industrial salt, combined with calcium chloride and magnesium chloride, causes rapid mechanical corrosion.

3. High Capacity & Flexible Formulations: The plant required automated multi-ingredient batching and high hourly throughput to meet peak winter demand.

2. Engineered Solution: Multi-Extruder Parallel Layout & Auto-Batching

To meet the client's stringent specs, our engineering team designed and delivered a turnkey Dry Double Roller Extrusion & Granulation Line featuring an automated multi-silo batching system and a parallel multi-extruder processing deck.

3. Core Machinery Breakdown (As Installed)
Module 1: Heavy-Duty Multi-Silo Automatic Batching System
1. Multi-Bin Loss-in-Weight Feeders: Heavy-duty storage hoppers continuously weigh and feed industrial salt, calcium chloride, and anti-rust additives with ±0.2% accuracy.
Corrosion-Protected Structure: Steel hoppers and belt structures are coated with specialized marine-grade epoxy coatings to prevent salt rust.

Module 2: Centralized Material Distributor & Multi-Extruder Deck
Rotary Overhead Distributor: The blended salt mixture is lifted via an enclosed belt conveyor to an overhead rotary distributor, which feeds the dry mixture evenly into multiple parallel Double Roller Extruders.
Forged Alloy Roller Sleeves: Rollers are forged from specialized anti-corrosive alloy steels to handle high-pressure compaction without premature sleeve wear.

Module 3: Flake Breaking, Screening & Closed-Loop Recycling
Rotary Flake Breaker: Gently crushes compacted salt sheets into hard polygonal granules (2.0--6.0 mm) with minimal fine dust.
100% Zero-Waste Loop: Undersized salt powder is separated by a rotary drum screener and routed automatically back to the extruder inlet for immediate re-compaction.

4. Project Highlights & Operational Performance

• 60% Energy Savings via Dry Compaction: Operates entirely without thermal drying or water injection, dramatically reducing operational expenditure (OPEX).
• Superior Granule Hardness: Extruded deicing pellets achieve high crushing strength, preventing degradation during bulk ocean shipment and pneumatic truck loading.
• Continuous Heavy-Duty Operation: The parallel multi-extruder setup allows maintenance on single units without stopping total plant production.

Client Feedback:
"The parallel double roller layout and automated distributor design delivered by Zhengzhou Gufeng gave us the exact production flexibility and high throughput we needed. The zero-drying dry compaction technology cut our energy bill significantly while producing high-grade deicing pellets that meet strict international highway standards."

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