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Definitions:
Multi-component Separations Involving High-Recovery or Sharp Product
Streams
(1) For sharp product streams, we normally use all-
sharp or high-recovery separation sequences to
Feed: Species Moles/hr NBP, T°C separate the feed into products. In such sequences,
H 2 :Hydrogen(Component A) 18 -253 each component being separated appears almost
C 1_ :Methane(B) 5 -161 completely in one and only one product.
C 2o :Ethylene(C) 24 -104
C 2_ :Ethane(D) 15 -88
C 3o :Propylene(E) 14 -48
C 3+ :Propane(F) 6 -42
(2) Key component in an all-sharp separation are
C 4 :Heavies(G) 8 -1 commonly defined by:

The light key (LK) is the lightest component in the

Products: AB, C, D, E, F, G
bottoms and the heavy key (HK) is the heaviest
component in the overhead.

(sequence a) (sequence b)
A
A A
(A , B ) (C , D ) (C )
B
H2 . C1 C22 .C2" C22
B B
A A C C
(overhead) C
D (LK)B C B D
E D
E
C2
(HK)C D D
M
E C
Feed .
E
T T S D D
H P
C C
H
A A
N
L
I
E B E E E
N I T F D F E
I T C D F
Z Z
E E G D G F F
E
R R
R (D ) E G
C 2" E E G
C12 .C1".C4 F E
C22 .C2" .C12 .C1".C4 (E , F, G )
(E , F)
(E ) F F F
C12 .C1"
(C , D , E , F, G )
C12 G G
(bottoms) G
D
d LK = d B
C1
E
P 0.98
R S
O
P P (component B’s recovery
L
A
N
I fraction in the overhead)
I
Z
T
T bHK = bC 0.98
E E
R
R
(F)
(component C’s recovery
(G )
C4 C1" fraction in the bottoms)

Possible Sequences
Questions: for a 4-Component Feed
A B C A B
How do you synthesize these two
industrial separation sequences ? A B C A B B
B C D B C C
C D C D
D D
Which sequence is “better” ? D D C
(Direct sequence)

Does your ranking vary with feed Sequence (a) and (b)
conditions ?

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Possible Sequences Possible Sequences

for a 4-Component Feed for a 4-Component Feed
A C A B A

A A B A A A
A A C B B C B B B
B B D C C C C
C D D
D D C B
B D D C
(Indirect sequence)

Sequence (c) Sequence (d) and (e)

SUBGROUPS FOR A FOUR-COMPONENT PROCESS FEED UNIQUE SPLITS FOR A FOUR-COMPONENT PROCESS FEED

Process Feed Feeds to Subsequent Splits for

First Separator Separators Products First Separator Splits for subsequent Separators

()
A A
(A) A
( )
() ( AB )
()
A B
B B
B C
C
A C

()
(B)
D
( BC ) B

()
B A
(C )
()
C B

()
A B
D C (C) C
B
D
( )
C
(D) C C
(D)
decreasing volatility D
D
() B
C

()
A D
B

()
C B
D C
D

NUMBER OF SEPARATORS, SEQUENCES,

Sequences of Two-Product Separators SUBGROUPS, AND UNIQUE SPLITS FOR SIMPLE
SEQUENCES USIGN ONE SIMPLE METHOD OF
The Combinatorial Problem:
Total number of possible sequences for N SEPARATION
components(products) if only type of separator is
used (e. g. ordinary distillation)= Number of S, G, U,

SN =
[2(N 1)]! Number of
Components
Separators in
a Sequence
Number of
Sequences
Number of
Subgroups
Number of
Unique Splits
N!( N 1)!
2 1 1 3 1
3 2 2 6 4
Number of unique feed and product groups = 4 3 5 10 10
N ( N + 1) 5 4 14 15 20
G= 6 5 42 21 35
2 7 6 132 28 56
8 7 429 36 84
Number of unique splits = 9 8 1430 45 120
10 9 4862 55 165
N ( N 1)( N + 1) 11 10 16796 66 220
U=
6

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n-Butylene Purification by Ordinary Distillation and Extractive Distillation

How do you get to following industrial separation sequence?
Feed: Relative Volatility*
Species Mole % (a)I (a)II 1-BUTENE COLUMN DEPROPANIZER
A: Propane 1.47 A
2.45 B
B: 1-Butene 14.75 C FEED
AB C3
A
C
1.18 1.17(nC 4/1-C 4) D
D
C: n-Butane 50.29 E E II
1.03 1.17(nC 4/T-2-C 4)
F
D: trans-Butene-2 15.62 1-BUTENE B

E: cis-Butene-2 11.96 2.50 C+S

CDE
F: n-Pentane 5.90
DE DE

Distillation
Extractive

Recovery
Solvenet
+ Solvent 2-BUTENES

*(a)I = adjacent relative volatility at 150 °F for separation

method I, ordinary distillation RECIRCULATED
SOLVENT
n-BUTANE
(a)II = adjacent relative volatility at 150 °F for separation C3 C
F
method II, extractive distillation with furfural.
(C 4H 3OCHO) EXTRACTIVE
DEOILER DISTILLATION SOLVENT STRIPPER
Products: A, B, C, DE and F. COLUMN

A
Definition:
A Extractive distillation is a form of distillation involving the
A B B
B addition of a solvent which modifies the vapor-liquid equilibria
C
C C of the components to be separated such the separation becomes
C
()
D D easier. The added solvent has a volatility lower than the
D
E E D components to be separated (i.e., the added solvent has a boiling
E
F F E II point higher than those of the components to be separated). Also,
it is usually introduced near the top of a column.
F

Examples of Extractive Distillation :

Mixture Solvent Example 1 Extractive Distillation
1-Butene(-6.3 °C) and 1,3 Normal Boiling Points, °C
Buradiene(-4.41°C) Acetonitrile(81.6 °C) Toluene(T)
MCH 100.9 ° MCH(M)
Nitric Acid(83 °C) and Water
(100°C) Sulfuric Acid(300 °C) Toluene 110.6 ° T = 9.7! C Phenol(P):C 6H 5OH
<

Phenol 181.75 °
distillation

Feed
extractive

Recovery
Solvent

Meth1 Cyclohexane(100 °C) and (Make-up

Benzene(80.1 °C) N-Formylmorpholine(243 °C) (Solvent) solvent)
Isooctane(99.2 °C) and doiuene CH 3C 6H 5: Toluene(T)
(Recycled
solvent)

(110.6 °C) Phenol(181.75 °C) CH 3C 6H 11: MCH(M)

Monomethyiamine(-6.3 °C). ① ②
Dimethylamine(7.4 °C) and
Trmethylamine(2.87 °C) Water(100 °C) Phenol(P)
Methy1 Cyclohexane(100 °C) and
Toluene(110.6 °C) Phenol(181.75 °C)
Acetone(56.2 °C) and Methanol
(62.5 °C) Water(100 °C)

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If :
1. T type of two-product separators are allowed.
2. Any mass-separating agent is recovered for recycle in
the separator following the one into which it is introduced.

Then :
SN =
[2(N 1)]! T N 1
N!( N 1)!
For example :
N = 4 components
Ordinary distillation only gives
SN = 5
Ordinary distillation plus extractive distillation with phenol gives
S N = 5(2)
4 1
= 40
N = 10
S N = 4862(T = 1)
S N = 4862(2)
10 1
=

HEURISTICS HEURISTICS
Heuristics Used in Heuristic and Evolutionary Strategies for Heuristics Used in Heuristic and Evolutionary Strategies for
Synthesis of Separation Sequences Synthesis of Separation Sequences
Type Separators
Type Separators
Reference Applied Heuristics Used Reference Applied Heuristics Used

Lockhart (1947) Distillation 1, 6 Freshwater & Henry (1975) Distillation 1, 2, 3, 5, 6

Harbert (1957) Distillation 2, 3 Mahaec (1976) and General 6, 11 plus evol.
Rod & Marek (1959) Distillation 4 Mahalec & Motard rules
Heaven (1969) Distillation 1, 2, 3, 5 (1977a, b)
Seader & Weaterberg General 1, 2, 3, 9, 11, 12,
Rudd and his co- General 1, 2, 3, 6, 8
workers (1971-73) 12, 13 (1977) 13, 18 plus
King (1971) and General 1, 2, 3, 7, 11 evol. rules
Nath & Motard (1978) General 9, 10, 11, 14, 15
Thomp son and King
(1972a, b) 17, 19 plus
Stephanopoulos (1974), General 7 plus evol. evol. Rules
and Stephanopoulos rules Doukas & Luyben (1978) Distillation 1
and Westerberg (1976) Hartmann (1979) and General 1, 2, 3, 6, 8, 16
Hartmann and 19
Hacker (1979)

Heuristic Rules.
1. Remove components one-by-one as overhead products.
2. Save the most difficult separation for last.
3. Favor 50-50 splits.
4. Sequence with the minimum total vapor flow.
5. Make high recovery fractions last.
6. Separate the more plentiful components first.
7. Choose the cheapest as the next separator.
8. Remove the thermally unstable and corrosive material early.
9. Perform least-tight separation first.
10. Favor sequences with the smallest product set.
11. Avoid separations using a mass-separating agent (MSA).
12. Remove a MSA from one of the products in another,
subsequent separation product.
Heuristic Rules
13. A separation method using a MSA cannot be used to isolate.
14. Favor distillation.
15. Separate first the components which might undergo undesirable
reactions.
16. Set splits fractions of the key components to pre-specified values.
17. Avoid extreme processing conditions.
18. Favor ambient operating pressure.
Nishida, Stephanopoulos, Westerberg(1980)

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Heuristic Synthesis of High-Recovery or Sharp, Multi-component A Simple, “Rank-Ordered,” Heuristic Method

Separation Sequences (Nadgir and Liu, 1983; Liu, 1987) (Nadgir and Liu, 1983)
Classification of Heuristics a. Decide the separation method to be used :

Method Heuristics (M Heuristics) : M1: Favor ordinary distillation

Favor the use of certain separation methods under given problem specifications
M2: Avoid vacuum and refrigeration
Design Heuristics (D Heuristics) :
Favor specific separation sequences with certain desirable properties b. Identify the forbidden splits, and essential first and last separations :
Species Heuristics (S Heuristics) :
Based on the property differences between the species to be separated D1: Favor smallest product set
S1: Remove corrosive and hazardous components first (also : reactive
Composition Heuristics (C Heuristics) : component, monomer)
Related to the effects of feed and product composition on separation costs S2: Perform difficult separations last
c. Synthesize the initial separation sequences :
Nadgir, V. M. and Y. A. Liu, “Studies in Chemical Process Design and Synthesis. 5. A
Simple Heuristic M ethod for Systematic Synthesis of Initial Sequences for C1: Remove most plentiful component first
Multi-component Separation,” AIChE Journal, 29, 926-934 (1983). C2: Favor 50/50 split
Liu, Y. A., “Process Synthesis: Some Simple and Practical Developments,” Chapter 6, d. Remove products and recycle stream as distillates.
in Recent Development in Chemical Process and Plant Design, Y. A. Mebee, Jr. and W.
R. Epperly, editor, Wiley, NY (1987), pp. 147-168 and 245-260. If not possible, take vapor from reboiler.

Heuristic M1 (Favor Ordinary Distillation)

“Rank-Ordered” Heuristics:
(1) The heuristics are to be applied one by one in the given order.
Higher-ranked heuristics appear first.
(2) If any heuristic is not important in, or not applicable to, the
synthesis problem, the next one in the method is considered.
a. All other things being equal, favor separation methods using only
energy separating agent (e.g., ordinary distillation), and avoid
using separation methods (e. g., extractive distillation) which
require the use of species not normally present in the processing,
i. e., the mass separating agent (MSA).
b. If the separation factor or relative volatility of the key components
LK , HK < 1.10, then the use of ordinary distillation is not

(3) If two heuristics give different recommendations regarding the recommended. or T < 10! C
next split, we should follow the guideline suggested by the c. An MSA may be used provided it improves LK , HK
.
higher-ranked heuristic.
For example, heuristic C1 overrules heuristic C2. d. When an MSA is used, remove it immediately follow the separator
into which it is used. In other words, always try to remove MSA early.

Heuristic M1 (Favor Ordinary Distillation)

A LLK Light Component
Minimum a required for consideration

B LK Light Key (e. g. 98% of B appears in overhead)

consideration of L/L extraction
Minimum b required for

of extractive distillation

C HK Heavy Key (e. g., 97% of C appears in bottoms)

D HHK Heavy
or

E HHK Components
Increasing
Normal
Boiling
Point BC
or LK , HK

Sounders, M., CEP, 60 (2) , 75-82 (1964)

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Example 2 Extractive distillation. Example 3 Azeotropic Distillation.

Add nonvolatile component to modify g’s Add volatile component that forms an azeotrope
with one or more of feed component
B HNO 3
BCS ternary heterogeneous
S-rich
S azeotrope
C-rich
HNO 3 C
B H 2O B+C
C azeotrop
a B+C azeotrope
H 2O

H 2O
C B B
S C
H 2SO 4 S ethanol
H 2SO 4 C
water
e. g., B = HNO 3 e. g., B = Ethanol
C = H 2O C = Water
S = H 2SO 4 S = Benzene

recycle

Extraction Reactive Distillation

⑤ B Add reactive component to modify g’s
B S
③B+S
a B/C distillation
②
B
S B+C C
⑦ C

C(+B) ⑥
① ⑥
B+C C
⑦ C+S
C ① ④
④ e. g., B, C = xylenes: a = 1.03
C+S S = organometallic: B, CS: a 30
(+B)
⑤ B : meta-xylene
③ ②
B S C : para-xylene
S : sodium cumene

Fuel oil
Burner
Heuristic M2 (Avoid Vacuum and Refrigeration)
High pressure
$/K cal

steam
a. All other things being equal, avoid excursions in temperature Cooling
Low pressure
and pressure, but aim high rather than low. steam
b. If vacuum operation of ordinary distillation is required, liquid- Heating
liquid extraction with various solvents might be considered. Room
i Temperature
temperature
c. If refrigeration is required, cheaper alternatives to distillation Cooling water
such as absorption might be considered. Ammonia refrigerant
Liquid nitrogen

Relative Costs of Cooling and Heating at Different

Temperatures (Berthouex and Rudd, 1977)

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100
Heuristic D1 (Favor Smallest Product Set)
Avoid:
10
Pressure of operation, atm

High ”P” and ”T”

or
1.0 When multi-component products are specified, favor sequences
Low ”P” and ”T"
that yield these products directly or with a minimum of blending,
0.1
unless separation factors or relative volatilities are appreciably
lower than those for a sequence which requires additional
-200 -100 0 100 200 300 400 500 600
Atmospheric boiling point, °C separators and blending.
Recommended Ranges of Pressure and Temperature
for Separation Operations (Souders, 1964)

Favor: High ”P” and Low ”T”

Low ”P” and High ”T"

An Example for Heuristic D1 An Example for Heuristic D1

Good Sequences for Different Product Sets :
Feed :
Normal Boiling T a. Products : A, BC, D
Species Mole% Point, T°C A
A Product Set for ”Separation“:
A 25 140 B B
20 B C (A, BC, D)
C C
B 25 160 D D D
20
C 25 180
20 b. Products : A, C, BD
D 25 200 Product Set for ”Separation“:
A A (A, B, C, D)
B B
B C
C C C BD
D D D D

Heuristic S1 Heuristic C1 (Remove Most Plentiful Component First)

Remove corrosive and hazardous components first. A product composing a large fraction of the feed should be
(Essential first separations) separated first, provided that the separation factor or relative
also reactive components and monomers volatility is reasonable for the separation.
1b moles
hr
A 70
Heuristic S2 (Perform Difficult Separations Last) 70A
T = 15! C
a 20B
a. All other things being equal, perform the difficult separations T = 15! C B 20
B
10C
last, C 10 C

A 70 A
b. Separations where the relative volatility of the key components 70A
is close to unity should be performed in the absence of non-key B 20 B
components. LK ,HK 1.05 ~ 1.10 20B
10C C 10
T 10! C
(Essential last separations)

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An Example for Heuristics S1, S2 and C1 :

An Example for Heuristics S1, S2 and C1 :
[See Rudd, et al. (1973), pp.197-199, Problem 9]
[See Rudd, et al. (1973), pp.197-199, Problem 9]
Industrial Sequence for Separating Chlorination and
Alkylation Products in the Manufacture of Detergent Industrial Sequence for Separating Chlorination and
Alkylation Products in the Manufacture of Detergent
I. Reactions :
II. Reaction Products to be Separated into Pure Components
(Chlorination) ( Relative
Flow Rate ) Normal Boiling
C12 H 24 + Cl2 C12 H 25Cl + HCl
(kerosene) (chlorine) (keryl (hydrogen
Species Mole/hr Point, T°C T
chloride) chloride)
A: HCl 1 -85 165
(Alkylation)
B: Benzene 5 80 134
C1 2H 5Cl + C 12H 25 - + HCl C: Kerosene 1 214 36
(keryl (benzene) (keryl benzene) (hydrogen
chloride) chloride) D: Keryl Benzene 1 250
E: Heavy Ends

An Example for Heuristics S1, S2 and C1 :

[See Rudd, et al. (1973), pp.197-199, Problem 9]

An Example for Heuristics S1, S2 and C1 :

[See Rudd, et al. (1973), pp.197-199, Problem 9] IV. Initial Separation Sequence
III. Key Questions :
A(HCl)
a. Species: Any corrosive and hazardous components?
Split A/BCD (essential first separation) A
B B(Benzene)
T : Any difficult separations? C B
b.
D C C(Kerosene)
Split C/D (essential last separation) C
D
D D(Keryl Benzene)
c. C1: Any plentiful components?
Split B/CD (desirable early separation)

Heuristic C2 (Favor 50/50 Split)

If the component compositions do not vary widely, sequences
which give a more nearly 50/50 or equimolal split of the feed
between the distillate (D) and bottoms (B) products should be
favored, provided that the separation factor or relative volatility
B
C D is reasonable for the split.
D(overhead) 50, 40, 5

F(Feed)
100 1b moles
hr

B(Bottoms) 50, 60, 95

D B
or
B D

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Coefficient of Ease of Separation (CES) Fractional recoveries of light-key(LK) and heavy-key(HK)

components in sharp or high-recovery separations :
If it is difficult to judge which split is closest to 50/50 Overhead Bottoms
and with a reasonable separator factor or relative
LK dLK ³ 0.98 bLK £ 0.02
volatility, then perform the split with the highest value
of the coefficient of ease of separation (CES) HK dHK £ 0.02 bHK ³ 0.98
As an approximation,
1 d 0.98 b 0.98
CES = f × ×
d b b 0.02 d 0.02
log[( ) LK ( ) HK ] LK HK

b d
To simplify the calculations of CES in sharp separations, we may
use CES = f ×
Where f = B / D or D / B Such that f 1
= T or ( 1) × 100

Examples of the Synthesis of Sharp or High-Recovery Separation Sequences

More on CES (Coefficient of Ease of Separation)
Example 1: Multicomponent Distillation Sequencing for
moles Thermal Cracking of Hvdrocarbons
Overhead, D
hr
e. g., 70, 60, 50, 30, 20 1. Feed
Separator

Feed Normal Boiling

moles Species Moles/Hr Point, T C T CES
100 A: Hydrogen 18 -253 92 23.0
hr B: Methane 5 -161 19.6
moles 57
Bottoms, B C: Ethylene 24 -104 16 14.6
hr D: Ethane 15 72 -88 18.1
e. g., 30, 40, 50, 70, 80 40
E: Propylene 14 -48
6 1.1
— Split ratio 30 40 50 30 20
F: Propane 6 -42 41 4.0
, , , , 1 G: Heavies 8 -1
D/B or B/D !"#
70 60 50 !"#
70 80
Example:
B/D D/B 2. Products : AB, C, D, E, F and G. CESA/BCDEFG =
D B
× T=
18
× 92 = 23.0
1( 1)
or
—T (Boiling-Point Difference) or LK ,HK
B D 72

D B 3. Key Questions :
or × T
—CES º B D
The larger the T or (a-1), the easier the separation
a. Products: Any multi-component products ?
D B b. Species: Any corrosive and hazardous components ?
or × ( 1)
B D c. rT: Any difficult separations ?
Close to one, 50/50 split d. Moles/hr: Any plentiful components ?
e. CES: Any easy and balanced (50/50) splits ?

1. M1 (favor ordinary distillation) and M2 (avoid vacuum and refrigeration):

Use ordinary distillation with refrigeration at high pressure. A
CES B
2. D1 (favor smallest product set):
Avoid splitting AB (a single product). Initial
A
Separation B
19.6
3. S1 (remove corrosive and hazardous components first): Sequence C
Not applicable.
18.1 D
E C
4. S2 (perform difficult separations last):
F D
Split C/D and E/F last, TC / D = 6! C
G E
TE / F = 16! C F
5. C1 (remove most plentiful components first):
Not applicable. G

6. C2 (favor 50/50 split):

Split AB/CDEFG with the largest CES = 19.6
and AB as a single product.

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A
A B
For separating CDEFG, splits C/D and E/F are performed last 24 C
16°C
so that the remaining splits to be chosen are CD/EFG and B 15 D
Difficult Split ? CD/EFG
CDEF/G. Split CD/EFG is done first since it has a larger CES C 14 E
6°C
D C C 6F
of 28.7: C ? CDEF/G
E D 8G
D
CD/EFG CDEF/G F D
E E E
f 28/39 8/59 G E
F Difficult Split
F F F
T 40 41 G
G G
CES 28.7 5.6
This sequence performs splits C/D and E/F last are it is exactly the
same as the one being practiced in the industry.

The second sequence can be obtained by making the split Another Initial Separation Sequence :
ABCD/EFG first, which has the second largest CES of 18.1.
A
A Single product A
A B
B ? A B
B C
16°C(last) CES
B C C C
C D =19.6 16°C
(large) C D D D
D D Last Separations
E CES
E
E =18.1 E
F 6°C(last) (2nd largest) F E
F E 6°C
G G F F F
G
G G

[See King, C. J., Separation Processes,

2nd Edition, McGraw Hill (1980), P.718]

Example 2: Multi-component Distillation Sequencing for n-Butylene

Purification by Ordinary and Extractive Distillation.

1. Feed: 3. Key Question :

Relative Volatility*
Species Mole % (a)I (a)II (CES)I (CES)II a. Products: Any multi-component products ?
A: Propane 1.47 2.45 2.163
B: 1-Butene 14.75 1.18 1.17 3.485 3.29 b. Species: Any corrosive and hazardous components ?
C: n-Butane 50.30 1.03 1.70 1.510 35.25
D: trans-Butene-2 15.62 c. Mole%: Any plentiful components ?
E: cis-Butene-2 11.96 2.50 9.404
F: n-Pentane 5.90
d. Relative Volatilities: Any difficult separations ?
e. (CES): Any easy and balanced (50/50) splits ?
* (a)I = adjacent relative volatility at 150 F for separation method I, ordinary
distillation
(a)II = adjacent relative volatility at 150 F for separation method II, ordinary

extractive distillation with furfural (C 4H 3OCHO)

DE
2. Products: A, B, C, and
D F. 1.47
(Example) (CES)I,A/BCDEF =B × ( 1)2 × 100 =
98.53
× (2.45 1)× 100 = 2.163

D B 5.90
(CES)II,ABCDE/F or × (d 1)2 × 100 = × (2.50 1) × 100 = 9.404
= B D 94.50

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Separation Sequencing for Example 2

1. M1 (favor ordinary distillation):
7. C2 (favor 50/50 split):
Use extractive distillation for C/D and ordinary distillation for all other splits.
(a) Split ABCDE/F first with the largest (b)Favor AB/CDE over A/BCDE
2. M2 (avoid vacuum and refrigeration): (CES)I = 9.404 (Split C/DE last)
Use refrigeration at high pressure. (Split C/DE last, avoid splitting DE) A/BCDE AB/CDE
A 1.47 f 1.47/92.63 16.22/77.88
A B 14.75
3. D1 (favor smallest product set): B (a-1)´100 145 18
C 50.30
Avoid splitting DE (a single product) C CES 2.301 3.749
D 15.62
D
4. S1 (remove corrosive and hazardous components first): E 11.95
E
Not applicable. F
F A
A
5. S2 (perform difficult separations last): A B B
Initial A
Split C/DE last (difficult extractive distillation), so that the added solvent B
Separation B
(furfural) can be recovered at the end without having to worry about its C C
Sequence C D
C
presence as a contaminant in earlier splits. D D
E D
E E
6. C1 (remove most plentiful components first): II
E
F F
C(50.30 mole %) dominates the feed, but it is not separated first due to S2.
Note: Heuristics are ranked in their relative importance according to their given order, e. g.,
Heuristic S2 overrides Heuristic C1

11