Abstract Water treatment sludge (WTS) is abundantly produced in the world; the waste contributes to the environmental problems. Therefore, for WTS utilization, aluminum leaching was employed using hydrochloric acid in this study. Al leaching efficiency increased from 72% to 80% as hydrochloric acid concentration increased from 1 to 4 M. Decreasing the particle size and increasing the temperature increased Al leaching efficiency. The proposed kinetic model revealed that the rate-controlling step followed a series of two leaching mechanisms: initially controlled by product-layer diffusion and then by a chemically controlled reaction. For instance, at 70 °C, the initial stage is well fitted by product-layer diffusion (R2 = 0.87) compared to R2 = 0.60 for chemical reaction; while for the second stage, R2 = 0.95 was observed via chemical reaction compared to R2 = 0.74 for productlayer diffusion. The activation energies in these two stages were 9.58 kJ/mol and 10.73 kJ/mol, respectively. The proposed model was well validated by using data from literature and thus will be useful for other applications of leaching and extraction processes. Keywords Waste . Environmental problem . Mechanism . Model . Chemical surface . Diffusion . Removal