A systematic procedure is proposed in this paper to incorporate the op
tions of merging and/or splitting streams from multiple origins in pro
cess synthesis. In particular, design problems associated with the hea
t exchanger networks (HENs) are discussed in detail. First, an input-o
utput system structure is described to facilitate the derivation of th
e modified LP and MILP models for calculating the design targets corre
sponding to the operating and capital costs. Next, construction proced
ure of a generalized stream structure is presented and the modified NL
P model for generating the optimal networks is formulated accordingly.
To accelerate the convergence rate of the corresponding iterative sol
ution process, an evolutionary short-cut method is provided to produce
feasible networks for use as the initial guesses. Two examples are al
so presented to demonstrate the effectiveness of the proposed approach
. The results show that, without increasing the operating costs, the c
apital costs of HENs can be reduced significantly by considering the p
roposed stream structure in design.