The research in this thesis considers novel innovative developments in established industrial processes that involve the use of recyclable polymeric particles as a partial replacement for aqueous media and chemicals. The application of the technology typically leads to water savings of over 80% and chemical savings of over 25%. These industrial processes may be characterised in that are considered inefficient and wasteful but nevertheless are considered economically vital. These diverse industries including laundry cleaning, leather manufacturing, textile garment processing, effluent treatment and metal beverage can manufacture. The outcomes of this research have made significant contributions to industrial best practice in such industries. In terms of academic research, the knowledge created in this thesis provides the basis for the application of CFD-DEM modelling to understand complex multi-phase and multi-component systems. In particular, the thesis advocates the application of the Free Surface Lattice Boltzmann Method for creating highly accurate simulations of multi-phase flow. In addition, the thesis offers opportunities for further research in novel plasma micro-reactors and their applications in diverse fields such as chemical synthesis, chemical engineering and biotechnology. The nature of the research is multi-disciplinary, and involved investigations across several fields including applied mathematics, biochemistry, chemistry, physics, and engineering. The projects also involved scale up from laboratory, pilot plant and full commercial scale production trials. Primary objectives were investigated through a series of six published patents. The three patents relating to the development of novel leather and textile processes were solely conceived and executed by the author. The patent related to the development of the plasma micro-reactor for ozone synthesis was conceived and executed jointly by the author and Professor Will Zimmerman (Sheffield University). The two patents related to the development of a novel metal cleaning and treatment process was conceived and executed jointly by the author and Dr. Robert Bird (Xeros Technology Group Limited).