Relative to the large effort that has been devoted to design problems of new processes, there has been relatively little work on developing methodologies for the optimal redesign of existing processes that can be performed with limited resources. The primary objective of the research is to perform a systematic study on the optimal redesign of existing processes through the use of synthesis simulation and optimization techniques. The investigation will develop methodologies for the optimal redesign problem of existing processes that will be applicable to other engineering disciplines. In particular, the design of (a) heat and power systems, (b) complex reactor networks, (c) reactor-separator systems, (d) separation systems and (e) systems that involve stochastic uncertainties will be addressed. Theoretical models coupled with insights are expected to result in redesign conceptual frameworks that will enhance the designer's ability to innovate.