Industrial Processes That Rely on Water

By Finlay Gilkinson – 04/06/2025

Water is a critical resource in numerous industrial processes, serving as a solvent, coolant, reactant, or transport medium. Its unique properties—abundance, thermal capacity, and chemical versatility—make it indispensable across various sectors. Below, we explore key industrial applications of water, their significance, and the challenges associated with water usage in industry.

1. Power Generation

Water is integral to energy production, particularly in thermal power plants (coal, natural gas, and nuclear). It is used in:

Steam Generation: Water is heated to produce steam, which drives turbines to generate electricity. In 2023, global thermal power plants consumed approximately 15% of freshwater withdrawals, according to the International Energy Agency.

Cooling Systems: Water absorbs heat from power plant equipment, preventing overheating. Cooling towers and once-through cooling systems are common, with the latter requiring large volumes of water from nearby sources like rivers or lakes.

Hydropower: Water’s kinetic energy is harnessed in dams to produce electricity, accounting for about 16% of global electricity production in 2024.

Challenges: High water consumption can strain local water resources, especially in water-scarce regions. Efficient cooling technologies and wastewater recycling are increasingly adopted to mitigate this.

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2. Manufacturing and Chemical Processing

Water is a cornerstone in industries like chemicals, pharmaceuticals, and food processing:

Solvent and Reactant: In chemical manufacturing, water dissolves substances or participates in reactions (e.g., hydrolysis). For instance, producing ammonia via the Haber-Bosch process requires water for steam reforming.

Cleaning and Sanitation: Food and beverage industries use water to wash equipment and ensure hygiene. For example, breweries consume 4-7 litres of water per litre of beer produced.

Pulp and Paper: Water is used to break down wood fibers and transport pulp during paper production. The industry accounts for roughly 5% of global industrial water use.

Challenges: Contaminated wastewater from chemical processes requires rigorous treatment to prevent environmental harm. Advanced filtration and zero-liquid-discharge systems are gaining traction.

3. Mining and Mineral Processing

The mining industry relies heavily on water for:

Ore Processing: Water is used to separate valuable minerals from ore through flotation or leaching. Gold and copper mining, for example, often use cyanide or acid solutions mixed with water.

Dust Suppression: Spraying water on mining sites reduces airborne dust, improving worker safety and environmental compliance.

Slurry Transport: Water transports mined materials as slurry through pipelines.

Challenges: Mining operations often operate in arid regions, increasing competition for water. Acid mine drainage, where water becomes contaminated with heavy metals, poses significant environmental risks.

4. Agriculture and Food Processing

While not always classified as “industrial,” large-scale agriculture and food processing rely on water-intensive processes:

Irrigation: Industrial agriculture uses vast amounts of water to irrigate crops. In 2024, agriculture accounted for ~70% of global freshwater use, per UNESCO data.

Food Processing: Water is used for washing, cooking, and cooling in processes like canning, dairy production, and meat processing.

Challenges: Over-extraction of water for irrigation can deplete aquifers, while runoff containing fertilizers or pesticides pollutes waterways. Precision irrigation and water reuse are critical solutions.

5. Textile and Leather Industries

Textile production is one of the most water-intensive industries:

Dyeing and Finishing: Water is used to apply dyes and chemicals to fabrics. Producing a single pair of jeans can require up to 7,500 litres of water.

Leather Tanning: Water is essential for soaking hides and rinsing chemicals during tanning.

Challenges: Toxic effluents from dyeing and tanning can contaminate rivers if not properly treated. Innovations like waterless dyeing and closed-loop systems are emerging to reduce water use.

6. Oil and Gas Industry

Water plays a key role in fossil fuel extraction and refining:

Hydraulic Fracturing (Fracking): Large volumes of water mixed with chemicals are injected underground to extract oil or gas. A single fracking well can use 2-8 million gallons of water.

Refining: Water is used for cooling, steam production, and separating hydrocarbons.

Challenges: Fracking’s high water demand and potential for groundwater contamination are contentious issues. Recycling produced water (water extracted during drilling) is a growing practice.

Sustainability and Future Outlook

Industrial water use, while essential, contributes to global water stress. Industries are increasingly adopting:

Water Recycling: Closed-loop systems reduce freshwater demand.

Efficient Technologies: Dry cooling in power plants and low-water manufacturing processes are gaining traction.

Regulatory Compliance: Stricter regulations, like the EU’s Water Framework Directive, push industries to minimize water use and pollution.

By 2030, global water demand is projected to exceed supply by 40% if current trends continue, per the UN. Industries must innovate to balance operational needs with environmental stewardship.

Industrial Processes That Rely on Water

Water is the lifeblood of many industrial processes, from energy production to manufacturing and mining. However, its intensive use underscores the need for sustainable practices. By embracing water-efficient technologies and recycling, industries can reduce their environmental footprint while maintaining productivity.

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