Although fly ash disposal is of environmental concern the quality of residues can be improved with respect to high value applications. Fly ash is considered as a potential source of aluminium and other strategic metals. Leaching and metal extraction behaviour of fly ash collected from Talcher Thermal Power Station have been thoroughly studied using sulphuric acid as extractant. The chemical and mineralogical composition of post-leached samples have been determined. Aluminium extraction by direct leaching at low acid concentration and ambient temperature is not suitable for high recovery. The extraction efficiency of aluminium increases significantly at a higher solid: liquid ratio. It is evident that the leachability of metals from fly ash depends on the nature of leaching medium, solid: liquid ratio, temperature and leaching time. (C) 2009 Elsevier Ltd. All rights reserved.