In this paper, a nonlinear constrained optimization strategy is proposed and applied to the reactor-regenerator section of a fluid catalytic cracking (FCC) unit. A nonlinear dynamic model of the fluid catalytic cracking process was used for the dynamic analysis of the plant and nonlinear multivariable control system. The model realistically simulates the riser-reactor and the one stage regenerator by assembling the mass and energy balances on the system of reactions. The model results were tested in a real-time application and the results were used to provide the initial values for the nonlinear control system design. A dynamic parameter update algorithm was used to reduce the effect of large modelling errors by regularly updating the model parameters. The constrained nonlinear optimization algorithm and strategies were tested in real-time on the fluid catalytic cracking reactor-regenerator. The results compared favourably to those from a linear multivariable controller. (C) 2000 Elsevier Science Ltd. All rights reserved.