<p>The increasing demand for sustainable manufacturing and stricter environmental regulations have prompted industries, particularly in aluminum and steel, to develop innovative recycling methods for metallurgical wastes like aluminum dross, ladle furnace (LF) slag, and lime fines. Often regarded as environmental liabilities, these materials offer considerable potential within a circular economy by reducing raw material consumption and mitigating environmental impacts. This study investigates the synthesis of calcium aluminate, a key material in steel refining that aids desulfurization and clean steel production while collectively recycling aluminum dross, lime fines, and ladle furnace slag. Hot water leaching was employed to effectively remove chloride from the dross, reducing its content to nearly zero while increasing the alumina (Al₂O₃) content from 73.2 to 84.4%. X-ray diffraction (XRD) analysis confirmed alumina as the predominant phase, with no salt phases detected, validating the leaching process. Post-leaching, the dross was sintered with lime fines and LF slag at 1300&#xa0;°C to form calcium aluminate phases, particularly mayenite (12CaO·7Al₂O₃), valued in steelmaking for its low melting point and ability to enhance slag–metal interactions. The optimal compositions, DC-2 (with an aluminum dross: lime ratio of 1.5:1) and DSC-3 (with aluminum dross, LF slag, and CaO in a ratio of 2:1:1.5), resulted in mayenite being the dominant phase, enhancing slag fluidity and refining efficiency. The sintered samples exhibited an average melting point of 1393&#xa0;°C, with some compositions demonstrating reduced melting points, enhancing slag behavior. SEM–EDS analysis confirmed CaO·Al₂O₃ as the predominant phase, while the crushing strength of pellets met industrial requirements. This study showcases the potential of converting aluminum dross, lime fines, and LF slag into high-value synthetic slags, advancing environmental sustainability and cost-effective steel production.</p> Graphical Abstract <p></p>