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The zinc content of basic oxygen furnace (BOF) sludges is too high for direct recycling into the blast furnace via the sinter plant, as excessive zinc concentrations are detrimental for the refractory lining of the blast furnace. However, by partial and selective removal of zinc from the BOF sludge, the residual sludge can be used as a secondary iron resource in the blast furnace. In this paper, BOF sludge was leached with aqueous ammonia, aqueous solutions of ammonium salts (chloride, carbonate, and sulfate), and aqueous mixtures of ammonia and ammonium salt. The mixtures of ammonia and ammonium salt could leach more zinc with respect to either the aqueous ammonia or the aqueous ammonium salt solution. The ammonia–ammonium carbonate (AAC) mixture was selected as the most suitable lixiviant due to the high zinc leaching efficiency in combination with a high selectivity towards iron; furthermore, this combination does not introduce unwanted chloride or sulfate impurities in the residue. The leaching process was optimized in terms of the liquid-to-solid ratio, total ammonia concentration, ammonium:ammonia molar ratio, temperature, and leaching time. The co-dissolved iron was precipitated as a hydroxide after oxidation of ferrous to ferric ions by an air stream, without co-precipitation of zinc, while the dissolved zinc could be easily recovered as zinc sulfide by precipitation with ammonium sulfide. The (almost) closed-loop process was successfully up-scaled from 10 mL to 1 L scale. Graphical Abstract

Selective Removal of Zinc from BOF Sludge by Leaching with Mixtures of Ammonia and Ammonium Carbonate