**Abstract**

This work presents a deep analyses of an environmentally friendly process to recover all valuable minerals contained in the spent potliner (SPL) such as graphite carbon and aluminum fluoride (AlF3) and production of sodium sulfate (Na2SO4) and gypsum (CaSO4) when H2SO4 is used as the leaching agent. The level of emission of hazardous gases such as HCN (weak acid) and HF are minimized by direct scrubbing of the HCN in aqueous AgNO3 solution to produce a stable silver cyanide (AgCN) product. The HF can be recovered as a liquid by condensation and used within the process and/or in production of metal fluorides such as the highlysoluble potassium fluoride (KF); a main source of fluoride in industry. Almost pure CO2 gas is also recovered from the process gas streams.

**Keywords:** aluminum production, spent potliner (SPL), leaching by H2SO4, aluminum fluoride recovery, graphite carbon recovery, zero-waste process
