Zinc-carbon batteries, which contain around 20% zinc, 35% manganese oxides and 10% steel, are currently disposed after use as land fill or reprocessed to recover metals or oxides. Crushed material is subjected to magnetic separation followed by hydrometallurgical treatment of the non-magnetic material to recover zinc metal and manganese oxides. The leaching with 2 M sulfuric acid in the presence of hydrogen peroxide recovers 93% Zn and 82% Mn at 25 degrees C. Alkaline leaching with 6 M NaOH recovers 80% zinc. The present study shows that over 90% zinc and manganese can be leached in 20-30 min at 30 degrees C using 0.1-1.0M sulfuric acid in the presence of sulfur dioxide. The iron extraction is sensitive to both acid concentration and sulfur dioxide flow rate. The effect of reagent concentration and particle size on the extraction of zinc, manganese and iron are reported. It is shown that the iron and manganese leaching follow a shrinking core kinetic model due to the formation of insoluble metal salts/oxides on the solid surface. This is supported by (i) the decrease in iron and manganese extraction from synthetic Fe(III)-Mn(IV)-Zn(II) oxide mixtures with increase in acid concentration from I M to 2 M, and (ii) the low iron dissolution and re-precipitation of dissolved manganese and zinc during prolonged leaching of battery scrap with low sulfur dioxide. (c) 2005 Elsevier B.V. All rights reserved.