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Research into on-plant recycling of by-products has been driven by the desire to improve the environmental and economic sustainability of the steel industry.1,2) One of the largest by-product streams in an integrated steel plant is dust from the basic oxygen steelmaking (BOS) process. Significant amounts of dust are formed in the BOS, where oxygen blown at supersonic velocities impacts on the liquid steel. This dust is made up of droplets of liquid steel, slag and fine particulates from the added fluxes.1–4) As steelmaking temperatures are in excess of 1 600°C, elements such as zinc can volatilise from the bath and enter the gas phase. As the gas phase is cooled, these volatilised metals can condense as separate particles or onto existing dust particles. Subsequent recycling of BOS dust back into the steelmaking route can therefore result in a recirculating and increasing zinc load that can result in process issues. Knowledge of the form in which the iron and zinc are found within the BOS dust is crucial in understanding how to best recycle the dust or how best to process it for recycling.2,3,5) A well-known issue with steel plant by-products is their high variability.1,2,5,6) In the case of BOS dust, the composiSelf-sintering of BOS Filter Cake for Improved Recyclability