Simulating the reactions in a complex system can lead to self-sustaining and energy efficient treatment of wastes in recycling promoting manner. In this contribution, the synergic combination of electric arc furnace dust (EAFD), mill scale, and secondary aluminum, in a form of waste foil, was researched aiming to use exothermal energy of reactions and to obtain environmentally favorable products. The secondary aluminum in the form of foil was prepared in different ways in order to develop aluminum surface and to be suitable for aluminothermic reactions. The commercial aluminum powder was used to determine optimal conditions using full factorial experiment design. After that, research was performed on aluminothermic reactions with the aluminum powder obtained from secondary aluminum foils. Results show that the secondary aluminum can be successfully used for a treatment of oxides bearing hazardous wastes in an energy efficient and environmentally friendly manner. The comparative life-cycle assessment revealed several advantages of using the secondary aluminum foil as a reduction agent compared to the conventional recycling of the secondary aluminum foil.