Handle SMTP 550 recipient-rejected errors with structured SmtpSendException

- Add SmtpSendException with smtpCode/smtpResponse/isRecipientRejected()
- smtpSend() $expect closure throws SmtpSendException (with code) instead of RuntimeException
- SmtpRelay::send() re-throws SmtpSendException so callers can inspect it
- request-access.php (new): catch 550 → roll back token+approval, return HTTP 422 with FR user message
- request-access.php (resend): catch 550 → HTTP 422 instead of silently claiming success
- StudentEmail::sendConfirmation(): catch SmtpSendException → log+false (submission not aborted)
- admin/actions/access-request.php: catch SmtpSendException post-approval → flash warning (recipient-rejected vs transient)

TODO.md

@@ -106,6 +106,16 @@
 - [x] Minimal horizontal padding inside columns (`var(--space-2xs)`)
 - [x] Align all column headings to the same baseline row (2-row grid via `display: contents`)
 
+## SMTP 550 recipient-rejected handling
+
+- [x] Add `SmtpSendException` — carries `smtpCode` + `smtpResponse`; `isRecipientRejected()` for 550–554
+- [x] `smtpSend()` `$expect` closure throws `SmtpSendException` (with code) instead of plain `RuntimeException`
+- [x] `SmtpRelay::send()` re-throws `SmtpSendException` so callers can react
+- [x] `request-access.php` (new auto-approve): catch 550 → roll back token + approval, return HTTP 422 with user-facing message
+- [x] `request-access.php` (resend path): catch 550 → return HTTP 422 instead of silent "access approved"
+- [x] `StudentEmail::sendConfirmation()`: catch `SmtpSendException` → log + return false (submission must not be aborted)
+- [x] `admin/actions/access-request.php`: catch `SmtpSendException` after approval → flash warning distinguishing recipient-rejected vs transient
+
 ## CSS refactor
 
 - [x] Move semantic HTML element baseline styles into common.css

app/public/admin/actions/access-request.php

@@ -52,9 +52,16 @@ try {
         $body = buildApprovalEmail($thesisTitle, $thesisAuthors, $accessUrl, $notes);
         $plain = strip_tags($body);
 
+        try {
             SmtpRelay::send($db, $request['email'], $subject, $body, $plain);
-
             App::flash('success', "Demande approuvée. Email envoyé à {$request['email']}.");
+        } catch (SmtpSendException $e) {
+            error_log('[access-request] Email delivery failed after approval: ' . $e->getMessage());
+            $smtpMsg = $e->isRecipientRejected()
+                ? "Demande approuvée, mais l'email n'a pas pu être délivré : adresse inconnue ({$request['email']})."
+                : "Demande approuvée, mais l'envoi de l'email a échoué (erreur SMTP). L'utilisateur devra relancer une demande.";
+            App::flash('warning', $smtpMsg);
+        }
 
     } elseif ($action === 'reject') {
         $db->rejectAccessRequest($requestId, $notes);

app/public/request-access.php

@@ -20,6 +20,7 @@ require_once __DIR__ . '/../bootstrap.php';
 require_once APP_ROOT . '/src/Database.php';
 require_once APP_ROOT . '/src/RateLimit.php';
 require_once APP_ROOT . '/src/SmtpRelay.php';
+// SmtpSendException is defined in SmtpRelay.php
 
 header('Content-Type: application/json');
 
@@ -114,6 +115,18 @@ if ($existingRequest) {
                 'message' => 'Un nouvel email d\'accès vous a été envoyé.',
                 'status'  => 'resent',
             ]);
+        } catch (SmtpSendException $e) {
+            error_log('Access request resend failed: ' . $e->getMessage());
+            if ($e->isRecipientRejected()) {
+                http_response_code(422);
+                echo json_encode([
+                    'success' => false,
+                    'message' => "L'adresse e-mail « {$email} » est introuvable sur le serveur de messagerie de l'ERG. Vérifiez l'orthographe ou utilisez une autre adresse.",
+                    'status'  => 'recipient_rejected',
+                ]);
+            } else {
+                echo json_encode(['success' => true, 'message' => 'Votre accès est déjà approuvé. Si vous n\'avez pas reçu l\'email, contactez l\'administrateur.']);
+            }
         } catch (Exception $e) {
             error_log('Access request resend failed: ' . $e->getMessage());
             echo json_encode(['success' => true, 'message' => 'Votre accès est déjà approuvé. Si vous n\'avez pas reçu l\'email, contactez l\'administrateur.']);
@@ -152,7 +165,31 @@ try {
         $body      = buildAutoApprovalEmail($thesis['title'], $thesis['authors'] ?? '', $accessUrl);
         $plain     = htmlToPlain($body);
 
+        try {
             SmtpRelay::send($db, $email, $subject, $body, $plain);
+        } catch (SmtpSendException $e) {
+            if ($e->isRecipientRejected()) {
+                // SMTP server does not know this address — roll back the approval
+                // so the user can retry with a valid address.
+                $db->getPDO()->exec(
+                    "DELETE FROM file_access_tokens WHERE request_id = {$requestId}"
+                );
+                $db->getPDO()->exec(
+                    "UPDATE file_access_requests
+                     SET status = 'rejected', admin_notes = 'Adresse e-mail inconnue du serveur de messagerie (550)'
+                     WHERE id = {$requestId}"
+                );
+                http_response_code(422);
+                echo json_encode([
+                    'success' => false,
+                    'message' => "L'adresse e-mail « {$email} » est introuvable sur le serveur de messagerie de l'ERG. Vérifiez l'orthographe ou utilisez une autre adresse.",
+                    'status'  => 'recipient_rejected',
+                ]);
+                exit;
+            }
+            // Transient send failure — access is approved, email may arrive later
+            error_log("[request-access] Email delivery failed for approved request #{$requestId}: " . $e->getMessage());
+        }
 
         http_response_code(200);
         echo json_encode([
@@ -201,6 +238,10 @@ try {
         ]);
     }
 
+} catch (SmtpSendException $e) {
+    error_log('Access request SMTP failure: ' . $e->getMessage());
+    http_response_code(500);
+    echo json_encode(['success' => false, 'message' => 'Erreur lors de l\'envoi de l\'email. Veuillez réessayer.']);
 } catch (Exception $e) {
     error_log('Access request failed: ' . $e->getMessage());
     http_response_code(500);

app/src/SmtpRelay.php

@@ -16,6 +16,31 @@ class SmtpProbeException extends \RuntimeException {
     }
 }
 
+/**
+ * Structured exception for SMTP send failures.
+ * Carries the 3-digit SMTP response code and the full server response.
+ *
+ * Notable codes:
+ *   550 / 551 / 553 — recipient address rejected (unknown user, policy, etc.)
+ *   421 / 450 / 451 — transient failures (try again later)
+ *   530 / 535       — authentication failure
+ */
+class SmtpSendException extends \RuntimeException {
+    public function __construct(
+        string $message,
+        public readonly int    $smtpCode   = 0,
+        public readonly string $smtpResponse = ''
+    ) {
+        parent::__construct($message);
+    }
+
+    /** True when the SMTP server permanently rejected the recipient address. */
+    public function isRecipientRejected(): bool
+    {
+        return in_array($this->smtpCode, [550, 551, 552, 553, 554], true);
+    }
+}
+
 /**
  * SMTP Relay — credentials stored in the DB, sending via a native PHP socket
  * client (no external dependencies).
@@ -391,6 +416,9 @@ class SmtpRelay {
 
         try {
             return self::smtpSend($s, $to, $rawMessage);
+        } catch (SmtpSendException $e) {
+            error_log('[SmtpRelay] ' . $e->getMessage());
+            throw $e;  // propagate structured exception so callers can react
         } catch (\Throwable $e) {
             error_log('[SmtpRelay] ' . $e->getMessage());
             return false;
@@ -463,7 +491,12 @@ class SmtpRelay {
         $expect = function (string $cmd, string $code) use ($send): string {
             $resp = $send($cmd);
             if (strncmp($resp, $code, strlen($code)) !== 0) {
-                throw new \RuntimeException("SMTP unexpected response to '{$cmd}': {$resp}");
+                $respCode = (int) substr(trim($resp), 0, 3);
+                throw new SmtpSendException(
+                    "SMTP unexpected response to '{$cmd}': " . trim($resp),
+                    $respCode,
+                    trim($resp)
+                );
             }
             return $resp;
         };

app/src/StudentEmail.php

@@ -99,7 +99,13 @@ class StudentEmail {
         $subject   = 'Merci — ton TFE a bien été enregistré';
         $htmlBody  = self::buildHtml($thesis);
 
+        try {
             $result = SmtpRelay::send($db, $to, $subject, $htmlBody);
+        } catch (SmtpSendException $e) {
+            // Confirmation email failure must not abort the successful submission.
+            error_log("[StudentEmail] SMTP error sending to {$to} for thesis #{$thesisId}: " . $e->getMessage());
+            return false;
+        }
 
         if ($result) {
             error_log("[StudentEmail] Confirmation sent to {$to} for thesis #{$thesisId}");