As demand for metals grows and raw materials become increasingly challenging, research is becoming more closely linked to everyday industrial life. In collaboration between Aalto University and Swedish metals and mining company Boliden, doctoral researchers are studying the challenges faced by smelters in Harjavalta, Finland, and Rönnskär, Sweden.
Boliden is one of Europe's leading metal companies. The company processes copper, zinc, and precious metals, among other things, which play a key role in the green transition and in construction and electronics solutions.
The collaboration between Aalto and Boliden dates back decades and has been close with both Boliden’s Harjavalta and Kokkola units. The latest form of collaboration is the international Bolidenpaketet doctoral programme, which involves metal smelters from Finland, Sweden, and Norway. The program expanded in 2022 and funds two doctoral researchers at Aalto at a time.
The doctoral thesis collaboration has strengthened the cooperation between Aalto's metallurgy research group and Boliden Harjavalta. At the same time, it has opened up new Swedish connections for Aalto with Boliden's Rönnskär production unit and the Luleå University of Technology.
"Expanded cooperation with Boliden Rönnskär and Luleå University of Technology has increased new technological and scientific expertise for all parties, including us here at Aalto. In addition, the collaboration strengthens researchers' international professional networks, which will benefit the entire industry in the long term," says Mari Lundström, Vice Dean of Aalto University School of Chemical Technology and Professor of Hydrometallurgy.
The topics of the doctoral theses arise from Boliden's current research needs.
"The experimental research environments at universities provide us with high-quality, reliable information. We contribute expertise, observations, and experience from five production units to the network. We also supply researchers with raw material samples and data," says Petri Latostenmaa, Research and Development Manager at Boliden Harjavalta.
Iida Pankka, a doctoral student at Aalto University, is researching the wear and tear of furnace materials in copper smelters at high temperatures as part of the Bolidenpaketet program. Although the materials are fireproof, they wear out over time and replacing them is a significant expense.
Part of Pankka's doctoral thesis, which will be completed in spring 2026, has been carried out at Boliden's smelters in Harjavalta and Rönnskär. The research has a direct impact on cost savings, but the results are being put into practice in stages through small-scale trials and process changes.
"The information obtained may be valuable for future thermal simulations and furnace optimization. During the work, we have also learned more about how brick linings work, which will help us find ways to reduce their wear," says Robert Johansson, Manager Process Development, Automation and Digitalisation at Boliden.
”Iida’s results will help us look into our process and operational practices that could be enhancing the observed brick wear mechanism, and hopefully develop best practices that could improve our PS converter life and ultimately reduce associated costs”, says Jane Mulenshi Gustafsson, Metallurgist Business Area Smelters at Boliden Rönnskär.
Henri Palomäki, also a doctoral student at Aalto, is studying the challenges posed by arsenic concentrations in copper ores as the energy transition accelerates demand for copper.
“The research also has practical significance for improving occupational safety and hygiene. As the composition of raw materials changes, it is important to continuously deepen our understanding,” says Latostenmaa.
Petri Latostenmaa, Research and Development Manager, Boliden HarjavaltaHigh-quality doctoral research conducted in collaboration with companies supports degree education at universities and ensures the quality of degrees, as teaching staff have strong expertise and an understanding of business and industrial needs.
Aalto postdoctoral researcher Mika Sahlman's collaboration with Boliden Harjavalta began with his master's thesis and led to a doctoral dissertation funded by Boliden Harjavalta, in which he studied the effects of nickel on copper electrorefining. Nickel is a valuable by-product of copper production, but in too high concentrations it causes problems.
"In my doctoral thesis, I determined the maximum nickel concentration in the electrolyte to be 20-27 grams per liter, depending on the characteristics of the process. I also developed a particle tracking device that can be used to image the movement of the anode slime in copper electrolysis and the effect of nickel on the behavior of the anode slime," says Sahlman.
“The study tested new methods for examining complex phenomena, which is extremely valuable to us. The topic is important for Boliden’s future competitiveness, as copper production involves increasingly demanding raw materials,” says Latostenmaa.
Sahlman continues his collaboration with Boliden as a postdoctoral researcher at Aalto University and will participate in the planning of the new Paketet program. In the future, Boliden will need doctoral-level research, particularly in the areas of processing demanding raw materials, improving material efficiency, and utilizing by-products.
Master’s theses are an important part of Boliden's research and development activities. Between 2022 and 2026, five master’s theses have been completed at Aalto University alongside the Bolidenpaketet program, many of which have led to employment in Harjavalta.
“Competition for expertise is intensifying. High-quality doctoral research conducted in collaboration with companies supports degree education at universities and ensures the quality of degrees, as teaching staff have strong expertise and an understanding of business and industrial needs,” says Latostenmaa.
Text: Marjukka Puolakka
Competence in metallurgy is needed as the energy transition increases the demand for metals, and the reuse of materials requires new competence.
Led by Professor Mari Lundström
Long-term collaboration in the form of a doctoral project enables knowledge transfer and dialogue, where both the company, the university and the doctoral student learn from each other.
