This study presents a comprehensive investigation of copper extraction from chalcopyrite concentrate using choline chloride–malonic acid (ChCl:Ma) deep eutectic solvent (DES) through an integrated experimental and modeling approach. The work began with determi- nation of the deep eutectic temperature (38 ◦C) for the ChCl:Ma system, which guided the selection of the optimal 1:1 molar ratio to ensure minimal viscosity and maximum solvent stability. The operating temperature range (50–80 ◦C) was strategically chosen based on TGA analysis confirming the solvent’s thermal stability below 120 ◦C, ensuring no solvent degradation during leaching experiments. Response Surface Methodology (RSM) with Central Composite Design (CCD) optimization revealed temperature and leaching time (24–72 h) as statistically significant parameters affecting copper recovery, with a highly predictive quadratic model (R2 = 0.99, p < 0.0001). Kinetic analysis using the shrinking core model identified a diffusion-controlled mechanism through a sulfur layer, supported by low activation energies (Cu = 29.09 kJ/mol, Fe = 38.16 kJ/mol). Comprehensive characteri- zation showed preferential chalcopyrite dissolution with direct conversion to elemental sulfur (XRD), formation of metalchlorocomplexes (UV-Vis), and excellent solvent thermal properties (TGA). These findings demonstrate ChCl:Ma DES as an effective medium for chalcopyrite processing, with a systematic methodology providing insights for sustainable non-aqueous metal recovery systems

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