The specific problem of non-converted reactant accumulation encountered in fed-batch reactor is a challenging task of process safety. In order to avoid such situation that may lead to a runaway reaction, the reaction kinetics and reactor dynamic must be known. In this work, an innovative approach to determine an optimal feed profile, based on a reaction kinetic and reactor dynamic, is presented. This approach was applied to the reaction system involved in the Morton International Inc. incident. Great improvements were observed in the control of the accumulation, decreasing the number of necessary experiments needed for the scale-up studies.