KBC (A Yokogawa Company) received the Gulf Energy Excellence Award for Energy Project of the Year (Downstream) for its flagship Profit Improvement Program® (PIP). During the Gulf Energy Information Excellence Awards in Houston, Texas, on October 16, 2025, the organizers presented the award to KBC, recognizing it among eleven distinguished finalists for advancing operational excellence, digitalization, and decarbonization through its partnership with Acelen at the historic Mataripe Refinery in Brazil.
Multi-Year Program Driving Efficiency and Digital Transformation
In 2022, Acelen and KBC initiated a multi-year PIP aimed at identifying, evaluating, and executing high-impact operational improvements. The approach integrated advanced digital tools with automation and real-time optimization to enhance energy efficiency, reliability, and long-term profitability—without requiring major capital expenditure.
“Our work with KBC has been pivotal,” said Rafael Rebouças de Araujo, Value Chain Optimization Leader at Acelen. “By integrating PIP outcomes with real-time optimization, automation, and energy management, we have strengthened refinery margins, reliability, and energy performance, while preparing both the facility and workforce for the next phase of digital operations.”
Key Outcomes and Performance Gains
The collaboration has delivered measurable, sustainable results, including:
*Over $100 million in cumulative annualized benefits, including $30 million per year from improved crude selection and linear programming optimization.
*Up to 6.5 vol% increase in middle distillate production through enhanced crude unit operation and diesel hydrotreater optimization—achieved without major Capex.
*30% reduction in flare emissions and zero hydrogen flaring driven by emissions tracking and loss minimization efforts.
*10% reduction in energy use during the first two years, enabled by strategic opportunity implementation and digital technologies.
*Improved reliability and cost efficiency, including $3–5 million in avoided labor costs through optimized maintenance planning.
Digital Solutions that Enable Continuous Optimization
As per the press release, KBC supported the transformation with its integrated technology suite, including Petro-SIM® process simulation software, Visual MESA Energy Real-Time Optimization, HX-Monitor, and Visual MESA Greenhouse Gas Emissions Management (TÜV Rheinland certified). These tools provided real-time visibility, predictive insights, and continuous optimization across production and energy systems.
A Model for the Future of Refining
“Our collaboration with Acelen demonstrates how true partnership and digitalization deliver meaningful and lasting results,” said Sanjay Bhargava, Global Director of Process Optimization at KBC. “Together, we are redefining the future of refining in Latin America, while Bringing Decarbonization to Life®.”
