Bhusaval is located at 21°02′50.56″N 75°47′15.99″E 21.0473778°N 75.787775°E. It has an average elevation of 209 metres (685 feet).
Bhusaval is located on the banks of the Tapi river, and it is the biggest taluka of Jalgaon district, situated on National Highway No. 6 (NH6). Bhusaval railway junction is one of the largest railway yards of the Indian subcontinent. The hinterland of Bhusaval is famous for banana cultivation. World Heritage famous Ajanta is about 60 km (via Jamner) from Bhusaval.
Bhusaval is also known as Bhusawal. The spelling "Bhusaval" is used by the Railways (Central Government), while the spelling "Bhusawal" is used by the municipality. Generally People magazine spells it as "Bhusaval" or "Bhusawal" according to their preference.
As of 2001 India census, Bhusaval had a population of 172,366 (It is estimated to cross 200,000 before 2010). Males constitute 52% of the population and females 48%. Bhusaval has an average literacy rate of 78%, higher than the national average of 59.5%; with male literacy of 83% and female literacy of 72%. 11% of the population is under 6 years of age. Mainly Leva Patidar is the biggest community in Bhusaval.