The transition of the European steel industry towards climate neutrality requires the large-scale de-ployment of Direct Reduction (DR) processes combined with electric melting. While DR is a mature technology in regions with access to low-cost natural gas, its competitive operation under European economic conditions remains a major challenge, particularly in view of high energy prices and the increasing use of hydrogen. Without substantial improvements in productivity and operational effi-ciency, there is a significant risk that Europe’s steel industry will lose global competitiveness during this transformation.

The superProDR project addresses this challenge by enabling Direct Reduction processes to be operated at superior productivity levels, even under demanding conditions such as high operating temperatures, variable raw material quality and increasing hydrogen shares. The project follows a dual strategy that combines advanced raw material preparation with state-of-the-art process moni-toring, modelling and digital operation support.

On the material side, superProDR develops and validates novel pellet coating concepts that miti-gate sticking phenomena and allow the use of lower-cost raw materials while maintaining high throughput and product quality. On the process side, the project advances beyond current state-of-the-art by applying coupled CFD–DEM simulations, innovative high-temperature experimental methods and data-driven tools to enable real-time assessment of process states and early detection of sticking risks.

By integrating physical experimentation, advanced modelling and digitalisation, superProDR deliv-ers new standards, validated models and practical operation support tools that allow DR furnaces to be operated closer to their productivity limits without compromising stability. The consortium brings together leading steel producers, research institutes and academic partners, ensuring industrial rel-evance, efficient knowledge transfer and a clear pathway towards large-scale implementation of high-productivity Direct Reduction in Europe.