Case Study: Bharat Petroleum Corporation Limited achieves ~$500K/year savings and improved blending performance with Honeywell’s OpenBPC

Bharat Petroleum Improves Blending Performance with Honeywell’s OpenBPC

Bharat Petroleum Corporation Limited’s Mumbai Refinery faced the challenge of meeting evolving fuel specifications (BS/Euro III–IV) while minimizing quality giveaway and reducing reblends during final product blending. To address this, the refinery selected Honeywell’s Open Blend Property Control (OpenBPC) to provide DCS‑independent, online blend property control across gasoline, diesel and fuel oil blends.

Honeywell implemented OpenBPC on five blenders with feasibility studies, configuration, DCS/BRC integration, commissioning and an ongoing maintenance contract. The Honeywell solution delivered measurable gains: an estimated ~$500,000 USD per year potential from improved diesel blending, reduced excessive octane in gasoline, a 15–20% increase in “First Time Right” batches, near‑100% uptime, and materially lower sulfur variability (total variability 47 vs 95) when OpenBPC was in control.

Bharat Petroleum Corporation Limited

Asawari Kelkar

Bharat Petroleum Corporation Limited