Intensified continuous mini-reactors working in high pressure and temperature conditions are particularly effective at coping with mass transfer limitations during three-phase catalytic reactions. They are highly non-linear, multivariable systems and behave differently from conventional batch, fed-batch or continuous non-intensified reactors. In this paper, the optimization and control of this new process are presented using a two-layer approach consisting of a hierarchical control structure with an optimization layer which calculates the set points for an advanced controller. The latter is based on the concavity of the entropy function and the use of thermodynamic availability as a Lyapunov function. The three-phase catalytic o-cresol hydrogenation performed under high pressure and temperature in a small-scale pilot of the RAPTOR® reactor designed by the French company AETGROUP SAS, is taken as a representative test example to illustrate the strategy. The performance of the control structure is illustrated by simulation.

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