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Multivariable model reduction is applied to two processes for simulation, multivariable single input-single output controller design, and singular value decomposition controller design. The model reduction tech-niques investigated fail to maintain some of the dominant characteristics of the full system. More-over, the controllers designed with the reduced models are all unstable when applied to control the full model. Insight into the causes of the failures are discussed in terms of the characteristics maintained by the reduction techniques and the structure of the controllers.