Due to the growing global demand for aluminiumAluminium and the high-energy consumptionEnergy consumption of primary production, efficient secondary routes have become a strategic priority. RecyclingRecycling and valorizationValorization of aluminiumAluminium dross, a by-product of smelting, is particularly important from environmental and economic perspectives. Black dross (BD) is a challenging waste stream due to its complex composition, including aluminaAlumina (Al2O3), metal oxides, halide salts, and residual metallic aluminiumAluminium. Instead of being treated as hazardous waste, BD can serve as a precursor for advanced ceramic materials. In this study, BD samples were investigated through a combination of calcinationCalcination, leaching, and sinteringSintering. Samples were first calcined to remove volatile halide impurities and convert metallic aluminiumAluminium into stable oxides. Thermochemical modellingModelling guided the selection of optimal calcination temperaturesCalcination temperature. The calcined powders were then leached with H2SO4 to extract aluminaAlumina-based compounds. The optimal composition, obtained after calcinationCalcination at 1500 °C with enhanced magnesiumMagnesium aluminate (MgAl2O4) spinel formation, was consolidated via pressureless sintering at 1500 °C. Pellet (Ø1.7 cm × 0.5 cm) formed under 44 MPa load to evaluate the effect of green density. Sintered product was characterized using by XRD, SEM, Archimedes density, and Vickers’ microhardness (HV) measurementsMeasurements. Results demonstrate that black dross can be successfully converted into dense spinel-based ceramics, providing a sustainable recyclingRecycling pathway while enabling potential applications in advanced structural materials. This approach offers both environmental benefits and the valorizationValorization of a challenging industrial by-product.