<p>This study investigated the reduction mechanism of iron-rich zinc-bearing spinel to separate and recycle Zn from steel dusts. Non-isothermal reduction experiments using thermogravimetric (TG) analysis revealed a two-stage weight loss process: one quick and strong stage for the key reactions (key stage) and one weak and long stage afterwards (tail stage). Derivative thermogravimetric curves further divided the key stage into three steps. With the increase of heating rates, the reduction reactions shifted to higher temperature regions. TG-MS analysis showed that CO₂ generated earlier than CO. Kinetic analysis indicated that the reduction process followed a crystal nucleation model. As the heating rate increased, both E_a and <i>A</i> showed a decreasing trend. Scale-up experiments confirmed complete Zn volatilization and metallic Fe formation after reduction at 1000&#xa0;°C for 2 h. Thermodynamic analysis elucidated that the spinel reduction process included four reduction reaction pairs of ZnFe₂O₄ to Fe₃O₄ and ZnO, Fe₃O₄ to FeO, FeO to Fe, and ZnO to Zn. Pairs 1 and 2 generated CO₂ earlier than CO, whereas Pairs 3 and 4 showed the opposite trend. This study provided important foundations for optimizing resource extraction from steel dusts, particularly for the efficient separations of Zn and Fe.</p>