This paper describes an integrated strategy for a hierarchical multilevel mixed-integer nonlinear programming (MINLP) synthesis of overall process schemes using a combined synthesis/analysis approach. The synthesis is carried out by multilevel-hierarchical MINLP optimization of the flexible superstructure, whilst the analysis is performed in the economic attainable region (EAR). The role of the MINLP synthesis step is to obtain a feasible and optimal solution of the multi-D process problem, and the role of the subsequent EAR analysis step is to verify the MINLP solution and in the feedback loop to propose any profitable superstructure modifications for the next MINLP. The main objective of the integrated synthesis is to exploit the interactions between the reactor network, separator network and the remaining part of the heat/energy integrated process scheme. (C) 2004 Elsevier Ltd. All rights reserved.