In Egypt, water treatment consumes about 365 000 tons of aluminum sulfate and produces more than 100 million tons of sludge per year. The common disposal system of sludge in Egypt is to discharge it into natural waterways. Toxicity of aluminum, environmental regulations and costs of chemicals used in water treatment and sludge treatment processes led to an evaluation of coagulant recovery and subsequent reuse. The present work aimed at aluminum recovery from sludge of El-Shiekh Zayd water treatment plant (WTP) to produce aluminum sulfate coagulant. Sludge was characterized and the effect of five variables was tested and the process efficiency was evaluated at different operating conditions. Maximum recovery is 94.2% at acid concentration 1.5 N, sludge weight 5 g, mixing speed 60 rpm, temperature 60 °C and leaching time 40 min. Then optimum conditions were applied to get maximum recovery for aluminum sulfate and compared to commercial coagulant on raw water of El-Shiekh Zayd (WTP).