This study emphasizes the modelling and experimental validation of results for the preparation of dry alkali metal chloride powder in a semi-continuous process starting from their aqueous precursor solution in spray drying with induction heating. Experiments were carried out on sodium chloride (NaCl) salt solution to determine the process parameters, liquid feed rate, drying air rate, and induction heating temperature on the proposed pilot scale plant. This work employs a modified version of the counter-current spray drying process comprising mechanisms of induction heating and mechanical pulsation for reciprocation of perforated plates to enhance drying performance. Meanwhile producing powder with relatively narrow particle size distribution with 87.3% overall solid collection efficiency from proposed pilot plant. Particle characteristics of collected dried powder from drying chamber were characterized for moisture content and particle size distribution. The Eulerian–Lagrangian approach was developed for CFD analysis to obtain particle phase properties such as trajectories, residence time, and size distribution along with gas-phase temperature and velocity profiles. Purpose of this study is to mitigate the limitations faced by traditional counter current spray dryer teristics in spray zone specifically more relevant for droplets contain dissolved solid.