Department of Bioproducts and Biosystems

Biorefineries

Biorefineries research group is led by Prof. Herbert Sixta. The group's research covers the entire value chain from the fractionation of the lignocellulosic biomass to valorization of the isolated biopolymers, with the aim of sustainably producing commodities analogous to fossil-based products.

CHEM_Bio_Marianna_Granatier_From wood to fiber — Marianna Granatier, From wood to fiber

Research themes:

1. Biomass fractionation - chemical pulping refineries and novel fractionation processes:

We investigate radically new energy and resource efficient production technologiesfor chemical pulping, e.g. Kraft-Oxygen Delignification (KrOxy) process and new dissolving pulp technologies. In addition, our research group develops novel biomass fractionation processes based on the utilization of Biomass valorisationsupercritical water and green solvents, e.g. gamma-valerolactone (GVL).

Investigation of novel fractionation technologies such supercritical water, and Organosolv fractionation methods simultaneously with the optimization of the conventional kraft pulping process;
Pulp characterizations, bleaching, purification (hemicellulose removal) and the adjustment of pulp properties.

2. Biomass valorisation:

Cellulose: We study conversion of cellulose e.g. into man-made cellulose fibers and all-cellulose composites.

Hemicelluloses: Our research topics include the valorisation of xylan from alkaline extractions, production of xylo-oligosaccharides and catalytic conversion of biomass-derived sugars into furans.

Lignin: Lignin is an interesting biomass component which can be converted into valuable products such as bio-oil. Lignin-cellulose blends can be used e.g. as precursor fibers for carbon fibers, or as natural dye in textiles.

Dissolving pulp production according to existing and new protocols
Production of man-made cellulose fibers from virgin cellulose pulp and cellulosic textile wastes by the Lyocell spinning process with emphasis on the Ioncell® fiber process
Chemical modification of regenerated cellulose fibers
Production of furanic-based platform chemicals from biomass-extracted hemicellulose
Production of bio-oil and monoaromatic compounds from various lignin sources by catalyzed and uncatalyzed hydrothermolysis.

Our versatile reactor portfolio enables flexible pulping experiments from small lab-scale (30 mL) to pilot scale (10 L), including both traditional (prehydrolysis) kraft and novel Organosolv processes. Elemental-Chlorine-Free (ECF) and Total-Chlorine-Free (TCF) bleaching techniques are readily available.

Our flagship research in biomass valorization is the production of novel man-made cellulose fibers for the circular economy by the dry-jet-wet spinning Ioncell® process, which convert cellulose from virgin wood pulp or cellulosic textile waste into high-quality, high-strength textile fibers. In addition, our research group is equipped with fiber characterization equipment and yarn spinning machinery. We also investigate in the conversion of extracted hemicelluloses and lignin to high value products such as furanic platform chemicals, monoaromatic compounds and bio-oil. Our lab developed advanced chromatography methods (HPLC, CE, IC, GPC) for comprehensive analysis of complex product mixtures.

Aalto University/Biorefineries monowave — Valorisation of hemicellulose

Examples of ongoing research projects:

Trash-2-Cash (EU Horizon 2020)
SolvRec (Business Finland)
iCom (Business Finland)
ALL-CELL (FiDiPro, Prof. Tatiana Budtova)
WoCaFi (ERC starting grant, Dr. Michael Hummel)
Tekide (ERDF)

ALL-CELL: From ultra-light to ultra-strong all-cellulose composites via green processing

Finland Distinguished Professor grant awarded to Prof. Tatiana Budtova (Center for Materials Forming of MINES ParisTech, France). The goal of the 4-year project (started 2016) is to imagine, prepare and characterize new fully bio-based materials, all-cellulose composites.

Feng Chen, Tatiana Budtova and Oona Korhonen - ALL-CELL team. Photo by Eveliina Jutila

Ioncell

Ioncell-F is a technology that turns used textiles, pulp or even old newspapers into new textile fibers sustainably and without harmful chemicals. The process converts cellulose into fibers which in turn can be made into long-lasting fabrics.

Awards:

The Ioncell-F process was granted the Global Change Award 2016 by the H&M Conscious Foundation, the Paper Recycling Award 2015 of the European Recovered Paper Council (ERPC), and the DIA Innovation Award 2018.

President Sauli Niinistö and Jenni Haukio at 2018 Finnish Independence Day reception. Photo: Vesa Moilanen/Lehtikuva

Mrs. Jenni Haukio’s gala dress in the Independence Day Reception 6.12.2018; photo: Vesa Moilanen, Lehtikuva. Textile design: Helmi Liikanen (ARTS), dress design: Emma Saarnio (ARTS)

A scarf made of Ioncell® fibers from recycled waste cotton and given to president Macron

Marimekko’s Unikko dress. It was produced form Ioncell®/Tencel™ blend woven fabric. Photo: Sebastian Johansson, dress design: Riikka Buri, Marimekko

The Ioncell dress group

γ-valerolactone biorefinery

γ-valerolactone pulping is a novel organic solvent fractionation process developed by Professor Herbert Sixta’s Biorefineries research group.

GVL biorefinery Photo: Aalto University / Anni Hanén

We urge not only for investment in pulping research, but also for the commitment of young researchers.Together we make pulping great again!

Herbert Sixta, head of the research group

The textile industry needs sustainable fibers produced from renewable or recycled sources, which can be recycled at the end of their life and which do not produce micro-plastics. The demand for textile fibers is growing due to population growth and living standards. Currently, most textile fibers are synthetic, e.g. polyester, and are made from non-renewable sources. Cotton cultivation causes environmental problems due to the high consumption of irrigation water, pesticides and fertilizers. When textiles made of synthetic fibres are washed and worn, small fragments are released, causing microplastic contamination.

Aalto University offers the opportunity to study the raw material chemistry and process engineering necessary for the development of a sustainable textile industry, thereby combining materials research with textile and fashion design.

Production of commodities from biomass is the most viable option in the foreseeable future to mitigate the climate changes.

The raw materials of novel man-made cellulose fibers that we are developing in our research group are virgin pulp and recycled cotton waste. Cellulose pulp is made from smaller trees, and thinning stimulates the growth of remaining trees, thereby increasing carbons storage. When pulp is used for long-lasting products like textiles, the carbon is stored in the product. The recycling of cellulosic textiles even prolongs the carbon sink

Research group members:

Fibre made from recycled cloth towels and hemp stronger than cotton

The tensile strength of fibres created with the Ioncell method is up to 2.5 times more than that of cotton, while an Ioncell knitted fabric made from recycled hemp withstands abrasion for twice as long as normal hemp fabric.

Solving the systemic challenges in textile and fashion industry

We need systemic and fundamental changes in the textile and fashion industry’s business model, including a deceleration of manufacturing and the introduction of sustainable practices throughout the supply chain; decreasing clothing purchases and increasing garment lifetimes.

Take Finland’s lead and choose clothes you don’t have to feel guilty about

An Aalto University-designed and -produced dress made of birch trees shows how one day we will all look—and feel—good in sustainable fabrics

Haukio and Niinistö. Photo: Vesa Moilanen/Lehtikuva

Jenni Haukio to wear gown made of sustainable Ioncell material at December’s Independence Day reception

Ioncell is a new technology that creates high-quality textile fibres from wood or recycled materials.

President Macron received a scarf made from old jeans with Ioncell-F technology

The sustainable textile process was introduced to the President during his visit to Aalto University on 30 August 2018.

Professor Herbert Sixta presented Marimekko fabric made with Ioncell-F technology to President Macron, Finland’s Prime Minister Juha Sipilä and Aalto University President Ilkka Niemelä. Photo: Aalto University/Mikko Raskinen

”Koivikko” scarf paving way for new textile fibres made out of renewable and traceable birch

Professor Herbert Sixta donated an Ioncell scarf to Sirpa Välimaa, Product Manager Dissolving Pulp, Stora Enso Oyj, in PulPaper Conference on 31 May in Helsinki.

Professor Herbert Sixta and Sirpa Välimaa. The scarf was donated to Sirpa Välimaa as an expression of gratitude for Stora Enso's great support for Ioncell process over many years. Photo: Sofi Vuojakoski

High performance man-made cellulosic fibres from old newspapers

Increasing consumption requires new ways to recycle waste. In Aalto University old newspapers were converted to textile.

Upcycling ‘fast fashion’ to reduce waste and pollution

Aalto’s Ioncell team presents their work at a meeting of the American Chemical Society.

Fibres from textile waste to be turned into new attractive consumer products

Trash textiles are a valuable resource that should not be left untapped. Aalto and VTT are participating in an EU project called Trash-2-Cash.

Awarded method makes textile fibre from waste cotton

A greener textile industry requires expertise in chemistry, design and economy, stresses Herbert Sixta who leads the development of Ioncell-F.

A process revolutionising cotton recycling wins the H&M Global Change Award

The Ioncell-F™ process adapted for the conversion of waste-cotton into new textile was awarded as one of five winners among 2,700 proposals.

Luxury fibre from recycled cardboard

Prize-winning spinning method can reduce the environmental hazards of textile production.

Related videos:

The fiber-matrix interface in Ioncell cellulose fiber composites and its implications for the mechanical performance

Mindaugas Bulota, Simona Sriubaite, Anne Michud, Kaarlo Nieminen, Mark Hughes, Herbert Sixta, Michael Hummel 2021 Journal of Applied Polymer Science

Designing High Performance All-Cellulose Composites by Dissolution/Swelling of Macro- and Nano-scale Cellulose Fibers

Feng Chen 2021

Exploring digital image correlation technique for the analysis of the tensile properties of all-cellulose composites

Feng Chen, Daisuke Sawada, Christophe Pradille, Michael Hummel, Herbert Sixta, Tatiana Budtova, Jean-Luc Bouvard 2021 Cellulose

Self-Assembled Nanorods and Microspheres for Functional Photonics : Retroreflector Meets Microlens Array

Guang Chu, Feng Chen, Bin Zhao, Xue Zhang, Eyal Zussman, Orlando J. Rojas 2021 ADVANCED OPTICAL MATERIALS

Challenges in Synthesis and Analysis of Asymmetrically Grafted Cellulose Nanocrystals via Atom Transfer Radical Polymerization

Gwendoline Delepierre, Katja Heise, Kiia Malinen, Tetyana Koso, Leena Pitkänen, Emily D. Cranston, Ilkka Kilpeläinen, Mauri A. Kostiainen, Eero Kontturi, Christoph Weder, Justin O. Zoppe, Alistair W.T. King 2021 Biomacromolecules

Improved stabilisation of graphite nanoflake dispersions using hydrothermally-produced nanocellulose

Katarina Dimic-Misic, Jean Buffiere, Monireh Imani, Kaarlo Nieminen, Herbert Sixta, Patrick Gane 2021 Colloids and Surfaces A: Physicochemical and Engineering Aspects

Separation of fiber bundles from willow bark using sodium bicarbonate and their novel use in yarns for superior UV protection and antibacterial performance

Jinze Dou, Marja Rissanen, Polina Ilina, Heidi Mäkkylä, Päivi Tammela, Simone Haslinger, Tapani Vuorinen 2021 Industrial Crops and Products

Research database

Published: 4.6.2018
Updated: 1.7.2021

Biorefineries

Research themes:

1. Biomass fractionation - chemical pulping refineries and novel fractionation processes:

Read more

2. Biomass valorisation:

Read more

Examples of ongoing research projects:

ALL-CELL: From ultra-light to ultra-strong all-cellulose composites via green processing

Ioncell

Read more about the Ioncell process and our projects at ioncell.fi!

Awards:

Ioncell fibers:

γ-valerolactone biorefinery

Research group members:

Related content:

Related videos:

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