This study presents a comprehensive thermodynamic optimisation and sustainability analysis of the
secondary copper smelting process for Waste Printed Circuit Board (WPCB) recycling. The study
investigates various scenarios with different proportions of WPCB in the input stream, ranging from
0 per cent to 100 per cent. Through thermodynamic modelling using FactSage™ version 8.1, the
optimisation process is conducted in three stages. The results of the thermodynamic modelling
indicate that the best-case scenario for WPCB recycling is achieved with a 40 per cent proportion of
WPCB in the input stream. This case exhibits a maximum copper recovery of 99.93 per cent while
minimising the formation of other waste. In addition to the thermodynamic analyses, environmental
factors such as the carbon emission index and resource utilisation efficiency are studied. The
40 per cent WPCB recycling case exhibits a resource utilisation efficiency of 93.055 per cent and a
carbon emission rate of 0.133. The present investigation highlights the significant benefits of a
40 per cent WPCB recycling scenario through a secondary copper smelting process in terms of base
metal recovery and energy efficiency, thus emphasising its potential for sustainable PCB waste
management and resource utilisation.