Introduction: The High Cost of Data Inefficiency in Refining Blends
The refining sector is on the brink of significant changes, with the accelerating pace of global energy transitions influencing the industry through 2040. McKinsey scenarios, including Further Acceleration (FA), Current Trajectory (CT), and Fading Momentum (FM), predict diverse impacts on demand. Key determinants such as EV adoption, biofuels, and ambitious net-zero policies are reshaping the industry. The primary driver behind the declining liquid fuel is road transport, putting refineries in OECD regions, particularly North America and Europe, at the highest risk of capacity reduction due to weakening margins and stricter regulations.
Meanwhile, the IEA’s Oil 2023 report highlights growing energy security concerns and a surge in clean energy investments, bringing peak oil demand into view faster than anticipated. Furthermore, shifting consumer behaviors and upstream supply challenges are poised to reshape refining economics and trade dynamics through 2028.
A typical schematic flow diagram of a delayed coking unit (Source:
Why Blending Data Matters More Than Ever
Accurate blending in petroleum refineries ensures product quality, regulatory compliance, and profitability. As refineries operate 24/7 and convert crude oil into various products, such as gasoline, diesel, and jet fuel blending, precision determines whether the final output meets market and legal standards. According to the U.S. Energy Information Administration (EIA), refineries adjust their outputs regularly to match demand and maximize efficiency. Improper blending can lead to suboptimal fuel properties, penalties, or costly reprocessing. Thus, achieving consistent and accurate blends is essential for operational efficiency and directly impacts the refinery’s bottom line.
Data: The Hidden Asset in Every Blending Operation
Fragmented data systems in refineries often lead to underutilization of critical blending information, causing inefficiencies and increased operational costs. To address these growing challenges, industry leaders are turning to digital transformation. According to ARC Advisory, embracing digital solutions is not just a trend but a necessity for modernizing oil and gas operations. In line with this, AspenTech emphasizes that advanced blend management systems can significantly enhance product consistency and operational control. Building on this approach, OMS integrates tank, analyzer, and lab data to create a unified system. As a result, clients have seen measurable improvements in yield, blending accuracy, and overall refinery efficiency.
Step-by-Step Roadmap for Digital Transformation of Blending Data
Step 1: Assess Your Current Data Landscape
A successful digital transformation begins with clearly understanding your existing data environment. According to Honeywell UOP and Emerson, conducting a comprehensive data audit is essential for identifying gaps, inefficiencies, and untapped opportunities within blending operations. This foundational step helps refineries pinpoint integration challenges and prioritize improvements. Recognizing this need, OMS offers a specialized Blending System Assessment that evaluates current data flows and systems. Through this assessment, OMS identifies weaknesses in data integration and recommends tailored strategies to enhance performance, laying the groundwork for more innovative, more efficient blending processes across the refinery.
Step 2: Define the Business Objectives of Your Data Transformation
Clear, measurable business objectives must guide digital transformation in the refining sector to drive meaningful change. Bain underscores the importance of well-structured KPIs for tracking progress and ensuring accountability, while PwC emphasizes the need to align digital efforts with operational goals in the energy sector. When applied to blending operations, this means targeting outcomes like improved accuracy, reduced losses, and increased efficiency. OMS takes this further by aligning transformation initiatives with specific KPIs, such as minimizing manual reblends and improving first-pass blend success. This results in measurable, value-driven outcomes that directly support operational excellence.
Step 3: Integrate Data into a Unified Digital Platform
Once business objectives are defined, the next step is to unify data into a single, accessible digital platform. OSIsoft’s PI System and Yokogawa’s Blending Package highlight how centralized platforms improve real-time visibility and enable data-driven decision-making across blending operations. This integration is critical for eliminating data silos and ensuring consistent process control. OMS addresses this need through its proprietary FPBM™ (Fusion Process and Blend Management) platform, seamlessly connecting tank data, analyzer inputs, and lab results. As a result, operators gain holistic oversight, faster response times, and improved blending accuracy—all essential for optimizing refinery performance. Step 4: Apply Advanced Analytics and AI Models
With unified data in place, the next step is to unlock its value through advanced analytics and AI. AspenTech’s Blend Optimizer and IBM’s oil and gas solutions demonstrate how AI and machine learning can reduce property giveaways, enhance blend quality, and maximize margins. A notable example is Petrobras, which leveraged AI to minimize octane giveaway, improving efficiency and profitability. Based on this approach, OMS applies hybrid models integrating AI with its proprietary FPBM™ platform. This powerful combination enables predictive forecasting and real-time optimization of blend strategies, ensuring smarter, faster, and more accurate decision-making in blending operations.
Step 5: Enable Real-Time Visibility and Dashboards
To sustain performance and support continuous improvement, real-time visibility is essential. AVEVA’s Unified Operations Center and Seeq’s advanced analytics tools showcase how real-time dashboards empower operators with timely insights, enabling faster, proactive decision-making. These dashboards not only enhance situational awareness but also drive operational efficiency. OMS delivers tailored, role-specific dashboards that provide visibility into blend performance, KPIs, and exception alerts. By putting actionable data at users’ fingertips, these dashboards support collaboration across teams, reduce response times, and help maintain blending precision—ultimately ensuring alignment with strategic goals and improving day-to-day operational outcomes across the refinery.
Step 6: Automate Data-Driven Decision Workflows
The final step in the digital blending transformation is automating decision workflows to drive speed, consistency, and reliability. Rockwell Automation and ABB emphasize that automation in refining not only streamlines operations but also minimizes manual intervention, reducing errors and delays. Refineries can respond faster and more accurately to changing conditions by embedding intelligence into workflows. OMS enables this through the complete automation of blend control processes, integrating data insights directly into operational decisions. As a result, human error and latency are significantly reduced, while blend quality and efficiency improve—ensuring that decisions are executed precisely and consistently across every operation.
Expected Financial and Operational Gains from Digital Blending Transformation
The financial and operational benefits of digital blending transformation for refineries are substantial. According to Schneider Electric and Wood, reducing product giveaway, especially in critical metrics like octane, can lead to significant cost savings. For instance, a mere 0.3 RON reduction in octane giveaway can result in millions in annual savings.
OMS has demonstrated this impact in a Latin American refinery, where its hybrid FPBM™ platform enabled a $2.1 million yearly reduction in octane giveaway.
Beyond financial returns, operational gains are equally compelling. GE Digital and Honeywell highlight how streamlined workflows and real-time data access reduce downtime and accelerate decision-making. These improvements lead to faster blend turnarounds and greater plant efficiency faster.
Common Pitfalls to Avoid During the Digital Shift
Digital transformation in refining promises substantial rewards—but only if executed thoughtfully. One major pitfall is underestimating the importance of clean, structured data. Gartner reports that 84% of organizations experience poor business outcomes due to low data quality, while MIT Sloan emphasizes the need for robust data practices. To combat this, OMS implements a real-time data validation framework that includes QA checks, anomaly detection, and historical reconciliation before analytics are applied.
Another common oversight is neglecting operator and engineer buy-in. Harvard Business Review and McKinsey cite cultural resistance and lack of engagement as reasons why 70% of digital initiatives fail. OMS addresses this through its eLearning Academy, which offers hands-on training, change management support, and certification to build user-level confidence.
Finally, misaligned technology choices can derail progress. Deloitte and EY warn that 30% of tech investments are wasted without process alignment. OMS avoids this through in-depth fit-gap assessments and functional alignment workshops.
Conclusion: From Roadmap to Real Results
Digital transformation in blending is no longer optional—it’s a strategic imperative. Boston Consulting Group reports that successful digital blending and process optimization can deliver between $2 million and $5 million in annual savings per refinery. The key lies in executing a well-structured, data-driven roadmap that aligns technology, people, and processes. Through its comprehensive Blending Data Transformation Assessment, OMS empowers refineries to achieve these outcomes. This engagement identifies system gaps, quantifies improvement opportunities, and delivers a clear, low-risk pathway to measurable value.
Refineries ready to unlock multimillion-dollar gains are invited to partner with OMS and begin the transformation today.
Projected Reduction in Giveaways and Associated Cost Savings
Are You or Your Refinery ready to unlock multimillion-dollar gains?
If your answer is “YES”, then you are invited to partner with OMS and begin the transformation today!
Just reach out to us directly via email at info@globaloms.com.
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Disclaimer: OMS eLearning Academy and ChatGPT collaborated as Humans and AI to generate this article for you.
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