A new approach for process intensification through process simplification is proposed. This approach is based on a mass-integration framework for reducing the number of processing steps for grassroots and retrofit designs. Two procedures are presented based on graphical and mathematical programming techniques. The process simplification task is aimed at synthesizing process configurations that involve the least number of processing steps while yielding a certain product from a set of raw materials. The new concepts of maximum extendible zones and product paths are introduced and incorporated into the design procedure. The solution identifies the simplest processes along with their configuration, stream distribution, and basic performance data.