The liquid-liquid extraction of zinc using D2EHPA as extractant has been investigated in this paper in order to recover zinc sulphate from an industrial effluent produced by Votorantim Co. (Brazil) which contains several metallic species such as cadmium, cobalt, iron, lead, calcium, magnesium, manganese and nickel. The study was carried out in two main steps: (1) extraction and stripping laboratory scale tests in order to assess adequate operational conditions for the favourable recovery of zinc from the effluent and (2) continuous pilot scale tests using a mixer-settler battery aiming to reproduce the bench results. In the laboratory scale experiments, operating variables such as the pH of the aqueous effluent (0.5-5.0), concentration of D2EHPA (5-50%,w/w) and aqueous/organic volumetric phase ratio (1/5-5/1) were investigated for the zinc extraction process; for the zinc stripping process, the organic/aqueous volumetric phase ratio (1/1-10/1) was studied by contacting a metal loaded organic phase with an industrial acid solution produced by the company in the electrolysis of zinc. The continuous mixer-settler tests have shown that zinc can be selectively and quantitatively removed from the effluent (around 98%) using 3 extraction stages (pH 2.5, [D2EHPA] = 20% (w/w) and A/O = 1), and other 3 stripping stages (O/A = 4). A final solution containing 125.7 g/L of zinc was obtained that could be sent directly to electrowinning. (c) 2006 Elsevier B.V. All rights reserved.