Alkali Fusion–Leaching Process for Non-Standard Copper Anode Slime (CAS)

Copper anode slime (CAS), obtained from non-standard anodes by pyro-hydrometallurgical electronic waste (e-waste) processing, contains high concentrations of lead, tin (as metastannic acid), and base (Cu, Fe, Zn), precious (Au, Ag), and technological metals (In, Ga, Ge), which limit the efficiency of conventional valorization methods. In this study, an integrated alkali fusion–leaching process was applied to non-standard CAS. Thermodynamic modeling defined the key parameters for selective phase transformations and efficient metal separation. These parameters were experimentally investigated, and the optimized fusion conditions (CAS:NaOH = 40:60, 600 °C, 60 min), followed by water leaching (200 g/dm3, 80 °C, 60 min, 250 rpm), resulted in >97% Sn removal efficiency. Simultaneously, Au and Ag losses were negligible, resulting in solid residue enrichment. Oxidant addition (NaNO3) did not improve Sn removal but increased Fe, Pb, and Ag solubility, reducing selectivity. The scaled-up test confirmed process reproducibility, achieving 97.75% Sn dissolution and retention of precious metals in the PbO-based residue (99.99% Au, 99.78% Ag). Application of an integrated thermodynamic modeling, laboratory optimization, and scaled-up validation approach to non-standard CAS provides a relevant framework for a selective, efficient, and scalable method addressing industrial needs driven by increased e-waste co-processing, contributing to sustainable metal recovery.