Rheological Characterisation and Processability Window of Denim-Derived Cellulose Solutions in NMMO for Fibre Spinning

N-methylmorpholine N-oxide (NMMO monohydrate) is widely used for cellulose fibre production, as in the Lyocell process. However, fibre spinning from denim wastes remains significantly more complex due to its higher viscosity, the presence of indigo dye, and NMMO’s temperature sensitivity. These factors together create serious challenges for denim dissolution and fibre regeneration. This study presents a comprehensive rheological and structural characterisation of regenerated cellulose fibres derived from waste denim dissolved in NMMO. Oscillatory and steady-state rheological tests were conducted across concentrations (4–8 wt%) and temperatures (60–90 °C) to determine optimal spinning conditions. A 6% denim/NMMO solution at 80 °C displayed the most favourable rheological balance within the investigated concentration window (4–8 wt%), moderate complex viscosity, well-defined viscoelastic transitions, and a Tan δ value (~0.94) consistent with stable jet formation in air-gap spinning. Steady shear tests confirmed strong shear-thinning behaviour and mechanical predictability, essential for spinneret extrusion. Thermal ramp experiments validated 80 °C as the upper safe limit, balancing flow processability with structural integrity while avoiding solidification or NMMO degradation. The identified rheological parameters fall within ranges reported for spinnable cellulose dopes in air-gap spinning systems, suggesting strong potential for fibre formation under controlled conditions. These findings establish a robust rheological framework for denim-derived cellulose in NMMO and provide a foundation for future investigations into controlled fibre spinning and process scale-up in sustainable textile recycling.