The authors evaluate the possibilities of modifying the chemical characteristics of refuse-derived fuels (RDF) that are processed from residual household waste by mechanical operations to achieve and assure quality targets for relevant chemical concentrations, especially for heavy metals and chlorine. Quality assurance in the production of RDF demands that, together with an enrichment of the calorific value, highly toxic waste components are selectively separated and concentrated in a small stream to produce high yields of a relatively low polluted fuel. Based on the method of material flow analysis, a process evaluation is developed that considers the aspect of minimizing hazardous chemicals along with classical process data such as yield and product quality. Data on specific concentration of hazardous chemicals in waste components and their distribution in residual household waste as well as the results from large-scale test runs using different separation techniques demonstrate that mechanical operations alone are insufficient for separating hazardous chemicals. In the test runs, chemical compounds such as chlorine, cadmium and lead were often concentrated in the product. Even using optimized techniques, the ability to reduce hazards in the product is limited due to the distribution of the element concentration in the various components of the waste stream.