In this paper, a complex industrial distillation system, designed in a trad
itional manner without considering the interactions of design and control,
is introduced and shown to be severely ill-conditioned, Through rigorous mo
delling and sensitivity analysis, a new control scheme is first proposed fo
r overcoming the history of operational difficulties experienced by the sys
tem. A simultaneous dynamic optimisation-based approach is then implemented
to highlight the economic and operability benefits that could have been ob
tained if design and control interactions had been systematically considere
d in the first place. (C) 2001 Elsevier Science Ltd. All rights reserved.