Production and marketing of heavy fuel oil (HFO) are an easy, effective and economical way to dispose off certain very heavy refinery streams such as short residue (SR, available from the bottom of vacuum distillation units) and clarified liquid oil (CLO, available from the bottom of the main fractionators of fluidized-bed catalytic crackers). Certain lighter streams such as heavy cycle oil (HCO), light cycle oil (LCO) and kerosene, are added to the heavy residual stock to improve its quality in terms of fluidity, combustibility, etc., to be marketed as fuel oil. The present study aims at optimization of the fuel oil blending process to maximize profit, minimize quality give-away, maximize production, minimize use of lighter products such as LCO and kerosene, and maximize the calorific value, etc. Several multi-objective optimization problems have been formulated comprising of two and three-objective functions and solved using the elitist non-dominated sorting genetic algorithm (NSGA-II). This evolutionary technique produces a set of non-dominating (equally good) Pareto optimal solutions from which the operator can choose the one that is most suitable (preferred point). Also, a fixed-length macro-macro mutation operator, inspired by jumping genes in natural genetics, has been used with NSGA-II to solve this problem. This modified algorithm leads to a significant reduction in the computational effort. Indeed, this adaptation can be of immense use in reducing the computational effort for other problems in chemical engineering. (C) 2006 Elsevier B.V. All rights reserved.