An investigation into the solubility of aluminium and lead chlorides in HC1-saturated zinc chloride solutions and the use of high-aluminium zinc residues in the production of zinc chloride solution is reported. The process developed involves leaching of the high-aluminium zinc residues with concentrated hydrochloric acid followed by HC1 gas treatment to reduce the concentration of aluminium and lead from zinc chloride solutions. The solubility of aluminium and lead chlorides in HC1-saturated solutions depends on the zinc chloride concentration. The optimum zinc chloride concentration for maximum reduction in the aluminium and lead levels is 30-55% and 53% (w/w) respectively. Under optimum conditions the aluminium and lead concentrations are reduced to less than 0.1 and 0.9 mg cm(-3) respectively.