A systematic approach for the synthesis of flexible and controllable p
lants is presented It provides a new quantitative measure of the flexi
bility and controllability of a design and allows the designer to syst
ematically evaluate different process structures and/or control system
s. An integrated approach based on the dynamic mired-integer nonlinear
-programming problem is introduced that consists of two stages in each
iteration of the algorithm. In this way, the effect of disturbances o
n the process design and operation, as well as its ideal performance u
nder a variety of control schemes can be estimated. The method is illu
strated using a mini-integrated plant as a case study.