Case Study: Bharat Petroleum Corporation Limited achieves improved product quality, increased yields and lower operating costs with Honeywell Profit Suite

Bharat Petroleum Improves Quality, Increases Yields, Cuts Costs with Honeywell Profit Suite

Bharat Petroleum Corporation Limited’s (BPCL) Mumbai Refinery — a complex facility processing about 12 million metric tons of diverse crudes — faced challenges in stabilizing interactive refinery units while increasing throughput and product yields. BPCL needed better control of crude and vacuum distillation columns, reformer and reactor temperature profiles, hydrocracker conversion, and to minimize hydrogen venting and product quality variation. To address these challenges BPCL engaged Honeywell and its Advanced Process Control (APC) solution, including the Honeywell Profit Suite (Profit Controller and Profit Sensor Pro).

Honeywell deployed Profit Controller, Profit Sensor Pro and engineering services using its Robust Multivariable Predictive Control Technology (RMPCT), developing inferentials (e.g., product sulfur, kerosene/ATF properties, viscosity, vacuum residue indices), furnace pass balances and integrated MIMO APC applications across Crude, HGU, HCU, LOBS and DHDS units. The Honeywell solution reduced variation in methane slippage and diesel sulfur, cut fuel gas and steam consumption, increased throughput and product yields, improved energy efficiency and product quality, and delivered documented cost reductions and monetary benefits verified by BPCL.

Bharat Petroleum Corporation Limited

V. Suresh

DGM (Tech)