Waterless Manufacturing – Can the Chemical Industry Thrive Without Water?

Water has always been central to chemical production. It is used to run reactions, cool equipment, clean machines, and mix reactants. It’s been the quiet workhorse behind everything from tablets to perfumes to plastics. It’s been abundant, affordable, and essential. But that era is soon ending.

The industrial sector consumes up to 22% of global freshwater, and the chemical industry ranks among the top three. Meanwhile, 40% of people live in regions facing water scarcity. Isn't it ironic that an industry that drives innovation and economic growth today relies heavily on a rapidly depleting natural resource? 

This has created a considerable challenge: can we reimagine chemical manufacturing without depending on water?

In response, a new intriguing concept is emerging: waterless manufacturing. It's not just a sustainability trend but a strategic plan leaning towards low-impact, sustainable chemical processes. 

Where is Water Used in Chemical Manufacturing?

Before we can devise ways to reduce water usage, it’s only right to understand just how much water is currently consumed in chemical manufacturing and where it all goes. Water is used in nearly every part of the chemical manufacturing process, from production to safety.

• As a Reaction Medium: In almost 90% of the common chemical reactions we know, water is the main medium or the ‘environment’ where the reaction actually happens. 
• In Temperature Control: Chemical reactions can get extremely hot very quickly, and water helps regulate these temperatures as a cooling agent. It is also used to generate steam, which powers reactors or equipment. 
• As a Cleaning Agent: After every production cycle, equipment like reactors, tanks, glassware, and pipes need to be washed with water to remove any contamination and prepare them for the next batch to run.
• Diluting mixtures: Concentrated chemicals need to be diluted down into just the right proportion. Water helps adjust the concentration and consistency, making it easier to handle, apply, or react.
• Testing & Inspecting Equipment: Before any new production in a reactor, water is often pumped through new or repaired systems to check for leaks or weak spots. This simple but safe and cost-effective method simulates how the system will handle real chemicals. 

These are just some significant areas where water is used – the list is long. Because water is embedded in nearly every process, reducing its usage or replacing it altogether requires major innovations.

What is Waterless Manufacturing?

Simply put, waterless manufacturing means producing chemicals in a better way that uses little to no fresh water. This can be achieved by reusing water already in the process, replacing it with other liquids, or skipping it altogether when possible.

Note that this doesn’t always mean “zero” water. Instead, it’s all about shifting towards a smarter, more efficient system where every drop of water is either reused or replaced. 

We can sum it up in three categories:

• Substitution: In this process, we can replace water with other solvents, like supercritical CO₂ or even air and plasma, mimicking the function of water in a production process.
• Dry Processing: This approach skips water altogether, using dry methods for different processes like mixing, granulating, or creating products.
• Internal Recirculation: Treating and reusing water within the facility itself, so freshwater discharge is not required.

Less Water Usage for Lower Carbon Emissions

Reducing water use isn’t just good for conserving it. It's also great for the planet’s carbon balance, and it actually helps to bring about carbon negativity. Ask how?

Every litre of water used in a plant needs to be pumped, heated, cooled, and treated, all of which require energy, and that energy typically comes from fossil fuels. 

BASF, a European multinational company, through its case study, found that when a pharma facility reduced its water consumption by 80%, it also slashed its indirect CO₂ emissions by 12%.

Technologies Enabling Waterless Manufacturing

Mechanochemistry

Mechanochemistry is a combination of ‘mechanics’ and ‘chemistry’. Here, mechanical forces like grinding or pressing can get the job done instead of using water or solvents to initiate reactions. It's a simpler and more sustainable way of carrying out reactions.

One of the most exciting startups in this field is Cinthesis, founded by Professor James Mack, a leader in mechanochemistry research. They use ball milling, a mechanical action, to synthesize ibuprofen. In this process, raw materials like isobutylbenzene and acetic acid are ground together in a ball mill, where mechanical energy drives the chemical reaction, eliminating the need for solvents. 

Supercritical CO₂ & Green Fluids

What if carbon dioxide could help save water? Supercritical CO₂, where CO₂ behaves like both a gas and a liquid, is making that possible. CO₂ is being used in place of water for chemical reactions, extractions, and cleaning processes.

Companies like Novartis and BASF already use this approach to reduce water use, lower emissions, and save energy. It's a smart way to turn a greenhouse gas into a tool for greener manufacturing. 

Dry Granulation & Continuous Processing

Dry granulation is a clever way to make tablets and powders without using water. This is especially useful in pharma, where keeping ingredients dry helps make medicines more stable and easier to store.

Companies like Pfizer are already using this method to reduce water and energy use during production. It’s not just smart, but it’s growing fast. The dry granulation market was worth $1.4 billion in 2023 and is expected to double by 2030. As more manufacturers look for cleaner, water-saving options, dry granulation becomes a go-to solution.

Plasma-Assisted Chemistry

Imagine cleaning and sterilizing surfaces without using a single drop of water. Plasma technology makes this possible. By using energized gas, known as atmospheric plasma, surfaces can be treated or sterilized with high precision.

A company called PlasmaSi is already implementing this. They’re using plasma to clean and modify surfaces on medical devices and other sensitive equipment, all while eliminating the need for water. This clean, efficient solution is perfect for industries where even the tiniest contaminant can make a big difference.

Closed-Loop Water Systems

Rather than completely eliminating water use, some companies are finding smarter ways to recycle it, reducing the need for freshwater.

One great example is Tata Chemicals in Gujarat, India. They’ve set up a closed-loop water recycling system that allows them to reuse water multiple times throughout the manufacturing process. The system purifies and reintroduces high-purity water back into the production cycle, thus being a sustainable option.

Why isn’t Everyone Doing it yet?

While these technologies have great potential, they haven’t been widely adopted (yet) for several reasons.

• Setting up systems like closed-loop recycling or supercritical CO₂ units can be expensive. The infrastructure investment is often too steep for many companies, especially smaller ones.
• Many manufacturers, particularly smaller or mid-sized businesses, may not know about these technologies or how to implement them effectively without expert guidance.
• Not all chemical processes can be easily adapted to work without water. For some reactions, water is still essential, limiting the use of waterless methods for certain types of production.
• In some areas, there aren’t strong regulations encouraging water efficiency. Modifying certain processes can require extensive research and development, which can be a big barrier for companies. 

How Can the Government Help?

Providing Financial Assistance

Governments can offer financial support to companies adopting waterless technologies. This could include grants, subsidies, tax breaks, or low-interest loans to help offset the high upfront costs of implementing new technologies like closed-loop systems or supercritical CO₂ units.

Promotion of Zero Liquid Discharge (ZLD)

Zero Liquid Discharge (ZLD) is a treatment process that ensures no liquid waste is discharged into the environment. It’s an important step toward water conservation and zero-waste manufacturing. The government should encourage all industries to adopt ZLD by offering incentives, such as tax rebates, financial grants, and technical support. 

Foster Public-Private Partnerships

Governments can facilitate collaborations between the public sector, private companies, and research organizations. These partnerships can lead to the development of more efficient waterless manufacturing technologies, shared knowledge, and reduced costs through collective resources.

 A Step Towards Sustainability

At Scimplify, we actively embrace green chemistry principles to positively impact the environment and the chemical industry. Our focus on sustainability drives us to continually explore methods that reduce water usage, lower energy consumption, and minimize the use of harmful chemicals.  

The future of manufacturing is becoming more sustainable, and technologies like waterless manufacturing are leading the charge. Governments, industries, and companies have a role in this transformation. By adopting greener practices and pushing for more responsible resource use, we can make a significant difference in combating environmental challenges.

Contact us at info@scimplify.com to discuss how we can meet your custom chemical product requirements while keeping sustainability at the forefront.