Abstract: A method is provided for efficient processing of spent potliner, separating and recycling/utilizing the liquid and solid products generated during processing. The method includes the steps of crushing and screening the potliner freed from metal debris, pulverizing the potliner suspended in a hot aqueous slurry by autogenous grinding in a tumbler in the presence of air, subjecting the potliner to a series of leaching, thickening and filtering steps followed by separation of the potliner into Bayer Liquor, solid sodium fluoride, quality carbon product and mineral matter characterized by low cyanide and fluoride leachability. About 85% of the water required for potliner processing is recovered and recycled into the process.