This paper presents a methodology for the design of an integrated fault detection and fault-tolerant control (FD-FTC) architecture for particulate processes described by population balance models (PBMs) with control constraints, actuator faults and a limited number of process measurements. The architecture integrates model-based fault detection, state estimation, nonlinear feedback and supervisory control on the basis of an appropriate reduced-order model that captures the dominant dynamics of the process and is obtained through application of the method of weighted residuals. The architecture comprises a family of control configurations together with a fault detection filter and a Supervisor. For each configuration, a stabilizing output feedback controller with well-characterized stability properties is designed through the combination of a state feedback controller and a state observer that uses the available measurements of principal moments of the particle size distribution (PSD) and the continuous-phase variables to provide appropriate state estimates. A fault detection filter that simulates the behavior of the fault-free, reduced-order model is designed, and its discrepancy from the behavior of the actual process state estimates is used as a residual for fault detection. Finally, a switching law based on the stability regions of the constituent control configurations is derived to reconfigure the control system in a way that preserves closed-loop stability in the event Of fault detection. Appropriate fault detection thresholds and control reconfiguration criteria that account for model reduction and state estimation errors are derived for the implementation of the FD-FTC architecture on the particulate process. Finally, the methodology is applied to the problem of constrained, actuator fault-tolerant stabilization of an unstable steady-state of a continuous crystallizer. (C) 2007 Elsevier Ltd. All rights reserved.