The topic “Zero Waste” has been in existence for several years in the industry, and the metallurgical industry has also made efforts to reduce the amounts of residues occurring and have started several investigations to cut down on metallurgical by-products which have to be landfilled. Especially, the additional costs for CO2 emissions in different metallurgical steps have led to investigations into alternative carbon carriers. Charcoal has been identified to serve as an ideal substitute due its CO2-neutrality. For the applications of this renewable carbon carrier in metallurgical processes, charcoal production by means of a carbonization process needs to be optimized. As a by-product during the heating of agricultural wastes or wood by excluding air, pyrolysis gas occurs. Due to the existence of combustible compounds in this gas, an application as a reduction agent instead of fossil carbon carriers in metallurgy is possible. Based on the prevention of dumping metallurgical by-products, an investigation has been developed to treat zinc- and lead-containing materials. To realize this, a dedicated process concept has been designed and developed. As the main focuses, the usage of the pyrolysis gas from charcoal production for the Waelz kiln process and the recycling of zinc- and lead-containing Waelz slag, resulting from the processing of steel mill dust in a vertical retort, have to be mentioned. Within this research, the process concept was executed from laboratory-scale up to pilot-scale testing, described in this article.