• Waste sodium acetate (NaAc) serves as an environmentally friendly additive for complete AlN removal and enhanced Al extraction from secondary aluminum dross (SAD).
• Co-sintering at 850°C achieved 93.19% AlN removal and 90.49% Al leaching efficiency, significantly outperforming control conditions.
• The process involves exothermic decomposition of NaAc, which facilitates the transformation of aluminum species into soluble phases like Na1.95Al1.95Si0.05O4.
• This method offers a cost-effective and sustainable route for hazardous SAD treatment, addressing both environmental risks and resource recovery.