Integrated Waelz Furnace Processing of Spent Zinc Carbon Batteries and Electric Arc Furnace Dust for Enhanced Zinc Recovery

This study presents an integrated thermal recycling approach for spent zinc–carbon batteries and electric arc furnace (EAF) dust using Waelz furnace processing at 1150–1200 °C. Carbon contained in battery residues acts as an internal reducing agent, promoting the reduction and volatilization of zinc-bearing phases such as ZnO and ZnFe₂O₄. The combined processing improves zinc recovery efficiency and enables the production of ZnO-rich secondary material, while iron- and manganese containing residues remain as potential by-products. The proposed method reduces the need for external reductants, enhances resource utilization, and provides an environmentally sustainable solution for managing zinc-containing industrial wastes.