Background Zamak is a family of alloys, with a base metal of zinc (Zn) and alloying elements of aluminium (Al), magnesium (Mg) and copper (Cu). It is used in injection-moulding in various industries (e.g. ironwork, automotive parts, die-cast toys). According to data from the European Foundry Association, 3.5 million tonnes of zamak was smelted in Europe in 2011. The companies in Europe that use and process zamak also generate an estimated 1 million tonnes of hazardous and non-hazardous waste every year, which is deposited directly into landfill sites, giving rise to significant environmental problems (e.g. soil pollution). However, this waste contains a variable amount of zinc alloy that can be recovered as zinc oxide. Zinc oxide is the fourth largest exported mineral worldwide: According to figures from the International Zinc Association, a total of more than 1.2 million tonnes was consumed worldwide in 2011, with Europe accounting for around 300 000 tonnes. Objectives The project aims to develop and test, at pre-industrial scale, a pilot plant using plasma technology to obtain zinc oxide from zamak waste (mainly foundry slag and sludge). The zinc oxide obtained will meet all the technical specifications required to allow for its reuse. The processes will be tested and validated in two industrial sectors: the manufacture of rubber and chemical catalysts. The new technology will enable significant reductions in the quantity of hazardous and non-hazardous waste that is currently sent to landfill. It will also increase the competitiveness and sustainability of this type of industrial process. Expected results: The main expected results are: 1. The demonstration of a new technology to facilitate the recovery of zinc oxide from industrial waste; and 2. The validation of the use of the recovered zinc oxide in the manufacture of products in the rubber and chemicals’ sectors. Over the course of the project, 1 600 kg of zinc oxide will be produced from 4 000 kg of residues. If successful, the beneficiary believes the process has the potential to exploit over 1 million tonnes of the waste in Europe alone.