The presence of numerous local optima makes optimization of fed-batch react
ors a challenging problem. In addition, the low sensitivity of the performa
nce index on the control policy makes it very difficult to determine the op
timal control policy accurately. As an alternative to iterative dynamic pro
gramming, we consider the application of the direct search optimization pro
cedure of Luus and Jaakola (AIChE J. 1973, 19, 760-766) with the recent ref
inements involving the use of a quadratic penalty function with a shifting
term to handle equality constraints. In using the optimization procedure in
multipass fashion, we use the extent of variation of the variables in a pa
ss to provide the region size for the beginning of the subsequent pass. In
establishing the optimal control policies for three fed-batch reactor model
s, we show that this approach provides a good way of solving such optimizat
ion problems.