The main goal for the future is to avoid landfilling of residual wastes from the iron and steel industry. Therefore, more metallurgical dusts, such as steel mill dusts, have to be recycled. These by-products contain a high percentage of valuable metals, which would contribute to the overall production efficiency, if recovered successfully. Another target is to improve existing recycling processes in terms of product quality and environmental sustainability, in order to avoid the production of recycled zinc oxide with low quality. The present work deals with the development and optimization of a two-stage process by the sustainable reprocessing of heavy metal residues in a Top Blown Rotary Converter. Dusts which are high in zinc, lead and iron coming from an Electric Arc Furnace used in the iron and steel industry, have been tested. The focus is the recovery of high quality zinc oxide, as well as the further utilization of resulting metal alloy and slag.