Process for making bright stock base oil products

Abstract

An improved process for producing bright oil base oils from a base oil feed stream via hydrotreating, the base oil feed stream comprising atmospheric residual feedstock and, where appropriate, base oil feedstock. The process typically involves subjecting the base oil feed stream containing the atmospheric residual feedstock to a hydrocracking step and a dewaxing step, and, where appropriate, hydrorefining, to produce base oil products, including bright oil grade base oil products with a viscosity of at least about 22 cSt at 100°C. This invention can be used to manufacture heavy-grade base oil products such as bright oils, as well as Group II and / or Group III / III+ base oils.

Description

Technical Field

[0001] This invention relates to a process for manufacturing a bright and slippery oil base oil product by combining an atmospheric residual oil feedstock with a base oil feedstock to form a combined feed stream and forming a bright and slippery oil base oil product from the combined feed stream via hydrogenation. Prior Technology

[0002] High-quality lubricating base oils, such as those with a viscosity index (VI) of 120 or higher (Group II and III), can typically be produced from high-boiling vacuum distillates, such as vacuum gasified oil (VGO), through the following processes: hydrocracking to increase the VI, followed by catalytic dewaxing to lower the pour point and cloud point, and then hydrorefining to saturate aromatics and improve stability. In hydrocracking, high-boiling molecules break down into lower-boiling molecules, increasing the VI but also decreasing viscosity and yield. To produce high-VI, high-viscosity base oils in high yield, the hydrocracker feed must contain a certain amount of high-boiling molecules. Typically, due to practical limitations in temperature and pressure, VGO has limited ability to recover extremely high-boiling molecules from atmospheric residue (AR) in a vacuum column. One possible way to feed higher-boiling-point molecules into a hydrocracker is to directly feed AR (alkaline residue), but this is generally impossible or impractical because AR typically contains materials that are extremely detrimental to the hydrocracker catalyst, including, for example, nickel, vanadium, microcarbon residue (MCR), and pitchene. These materials shorten the hydrocracker catalyst lifetime to an unacceptable degree, making the use of such feed impractical.

[0003] One approach to using difficult whole crude oil and other intermediate feedstocks for base oil production involves first treating the feedstock in a solvent deasphalting (SDA) unit, such as AR or vacuum residual oil (VR). This treatment is often necessary to separate most of the unwanted materials while producing deasphalted oil (DAO) with acceptable hydrocracker feedstock quality. However, the extremely high capital requirements and operating costs of such SDA units, along with the monolithic process approach, make them an undesirable alternative. Other methods have been implemented that attempt to minimize or eliminate the need for solvent deasphalting steps, but have not yet offered significant benefits in terms of cost or other process improvements.

[0004] The production of Group III base oils and finished motor oils typically requires the use of expensive and limited-supply viscosity index improvers, such as polyalphaolefins, or other costly processing technologies, such as gas-liquidation (GTL) feedstocks or, for example, multiple hydrocracking processes of mineral oils. The production of Group III base oils also often requires high-quality feedstocks and high-conversion processes, sacrificing product yield to meet Group VI targets. However, despite ongoing industry efforts, relatively inexpensive and suitable feedstocks and simplified processes for manufacturing these products remain to be developed and commercialized.

[0005] Using conventionally available crude oil is generally not economical for producing higher-grade heavy base oils, partly because such feedstocks typically do not contain sufficient amounts of the molecular species required to produce such heavy grades. Typical vacuum gasification (VGO) feed fractions used to produce heavy neutral (HN) base oils end at only 1050 to 1100°F, with base oil viscosity limited to 11 to 12 cSt (measured at 100°C). The molecules required to produce higher-grade heavy base oils are not abundant in these typically available feed fractions. Processing such feedstocks to produce heavier fractions introduces excessive heteroatoms (such as nitrogen) and aromatics, and requires extensive pretreatment and high-intensity conversion. The resulting low yields make this process uneconomical using typical available feedstocks. Therefore, it is preferable to utilize feedstocks suitable for producing higher-grade heavy base oils, such as feedstocks with higher purity, lower aromatic content, and higher VI at the high boiling range of interest, as the source of heavy base oil products.

[0006] For higher-grade bright lubricant base oils, the above considerations are also worth noting. Bright lubricants are very high-viscosity base oils with a normal boiling point (NBP) of 1000℉ or higher and a viscosity at 100℉ ranging from approximately 22 (or higher) to approximately 30 cSt. The molecular composition of such bright lubricant base oils typically exceeds that of typical VGO oils used in the production of neutral oils (such as 600N and other products). Bright lubricants are usually produced from vacuum residual (VR) or atmospheric residual (AR) feedstocks. Because both VR and AR contain significant concentrations of molecules unsuitable for base oils, such as asphaltene, microcarbon residue (MCR), and nitrogen-containing molecules, in addition to catalyst poisoning from nickel and vanadium-containing molecules, these feedstocks typically require pretreatment to improve their quality. Typically, such VR and AR are adequately pretreated in solvent deasphalting units using propane solvent (PDA) to achieve acceptable yields and catalyst lifetime in base oil hydrocracking (HCR) units. HCR then processes and cracks the deasphalted oil (DAO) to increase the viscosity index (VI) and produce waxy bright oil. The waxy bright oil is then dewaxed to lower the pour point and cloud point, and then hydrorefined to remove trace impurities.

[0007] Despite progress in producing base oils from diverse and challenging feedstocks, further process improvements are needed to utilize different feedstocks and increase the yield of higher-quality, heavier base oil products, including lubricating oil base oils. Summary of the Invention

[0008] []

[0009] This invention relates to a process for producing bright and lubricating oil base oil products via hydrogenation of a base oil feed stream. While not necessarily limited thereto, one objective of this invention is to provide a process for producing bright and lubricating oils that does not require solvent deasphalting of the feedstock. An additional objective is to provide increased yields of bright and lubricating oil base oils.

[0010] Typically, the first process according to the present invention comprises manufacturing a bright lubricant base oil by: providing an atmospheric residual oil feedstock, which may be combined with conventional base oil feedstocks, as a base oil feed stream; contacting the base oil feed stream with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracking product; separating the hydrocracking product into a gaseous fraction and a liquid fraction; contacting the liquid fraction with a hydrodewaxing catalyst under hydroisomerization conditions to produce a dewaxing product; and, if applicable, contacting the dewaxing product with a hydrorefining catalyst under hydrorefining conditions to produce a hydrorefined dewaxing product. Typically, the atmospheric residual oil feedstock has an API specific gravity greater than about 25° API, a nickel and vanadium content less than about 2 ppm, an MCR less than about 1% by weight, and an asphaltene content less than about 500 ppm. This process produces a bright lubricant base oil product with a viscosity of at least about 22 cSt at 100°C. In some cases, this process can also provide beneficial yield improvements for one or more base oil products compared to using feedstocks that do not include atmospheric residual oil components.

[0011] This invention also relates to a method for modifying a base oil process for producing bright and slip base oils by adding an atmospheric residual oil feedstock to a base oil feedstock in a conventional base oil process. The conventional base oil process includes subjecting the base oil feedstream to a hydrocracking step and a dewaxing step to form a dewaxed product comprising light and heavy products. Therefore, the modified bright and slip base oil process includes: combining an atmospheric residual oil feedstock and a base oil feedstock to form a base oil feedstream; contacting the base oil feedstream with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracking product; separating the hydrocracking product into at least a gaseous fraction and a liquid fraction; contacting the liquid fraction with a hydrodewaxing catalyst under hydroisomerization conditions to produce a dewaxed product; and, where appropriate, contacting the dewaxed product with a hydrorefining catalyst under hydrorefining conditions to produce a hydrorefined dewaxed product. Typically, this atmospheric residual oil feedstock has an API specific gravity greater than about 25° API, a nickel and vanadium content less than about 2 ppm, an MCR of less than about 1% by weight, and an asphaltene content of less than about 500 ppm. Compared to using feedstock components that do not include atmospheric residual oil feedstock, the modified process produces bright lubricating base oil products with a viscosity of at least about 22 cSt at 100°C, and can also provide beneficial yield improvements for one or more base oil products.

[0012] The present invention further relates to a process for manufacturing a bright lubricating oil base oil with a viscosity of at least about 22 cSt at 100°C by the following operations: separating a base oil feed stream containing atmospheric residual oil feedstock and, where appropriate, base oil feedstock, into vacuum gasification oils with a front fractionation point of about 700°F or higher and a rear fractionation point of about 900°F or lower, to form a medium vacuum gasification oil (MVGO) fraction and a heavy vacuum gasification oil (HVGO); contacting the HVGO fraction with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracking product; separating the hydrocracking product into a gas fraction and a liquid fraction; hydrodewaxing the liquid fraction to produce a dewaxed product; and, where appropriate, hydrorefining the dewaxed product to produce a hydrorefined dewaxed product. Typically, this atmospheric residual oil feedstock has an API specific gravity greater than about 25° API, a nickel and vanadium content of less than about 2 ppm, an MCR of less than about 1% by weight, and an asphaltene content of less than about 500 ppm. Compared to using feedstock components that do not include atmospheric residual oil feedstock, this process produces bright lubricating base oil products with a viscosity of at least about 22 cSt at 100°C.

[0013] The present invention further provides a process for manufacturing base oil products from medium vacuum gasification oil (MVGO) fractions by means of the following operations: contacting the MVGO fraction with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracking product; separating the hydrocracking product into a gas fraction and a liquid fraction; contacting the liquid fraction with a dewaxing catalyst under hydroisomerization conditions to produce a dewaxing product; and, where appropriate, contacting the dewaxing product with a hydrorefining catalyst under hydrorefining conditions to produce a hydrorefined dewaxing product; wherein the viscosity index of the dewaxing product and / or the hydrorefined dewaxing product is 120 or higher after dewaxing. Simple Explanation of the Diagram

[0014] []

[0015] The scope of this invention is not limited by any representative figures accompanying this disclosure and should be understood to be defined by the scope of the claims in this application. Figure 1 is a block diagram of a general prior art process for manufacturing base oil products. Figure 2a is a general block diagram of one embodiment of the process according to the present invention, which uses an atmospheric residual oil (AR) or a mixture of vacuum gasified oil (VGO) and AR (VGO / AR) to manufacture base oil. Figure 2b is a general block diagram of one embodiment of the process according to the present invention, which uses medium vacuum gasification oil (MVGO) fraction from atmospheric residual oil to manufacture Group III / III+ base oil products and uses heavy vacuum gasification oil (HVGO) residual fraction from atmospheric residual oil or a blend of VGO and HVGO (VGO / HVGO) to manufacture heavy base oil products. Implementation

[0016] [] Cross-reference to related applications

[0017] This application claims priority to U.S. Provisional Application No. 63 / 141,962, filed on January 26, 2021, the entire disclosure of which is incorporated herein by reference.

[0018] Although one or more illustrative embodiments are provided herein, the disclosed processes can be implemented using many techniques. The disclosure is not limited to the illustrative or specific embodiments, drawings, and techniques described herein, but includes any exemplary designs and embodiments illustrated and described herein, and modifications can be made within the scope of the appended solutions and their equivalents in the full range.

[0019] Unless otherwise stated, the following terms, technical terms, and definitions apply to this disclosure. If a term is used in this disclosure but is not explicitly defined herein, the definition from the IUPAC General Catalogue of Chemical Terminology, 2nd Edition (1997) may apply, provided that the definition does not conflict with any other disclosure or definition applied herein, or renders any technical solution to which that definition applies unclear or invalid. If any definition or usage provided by any document incorporated herein by reference conflicts with the definition or usage provided herein, the definition or usage provided herein shall be understood to apply.

[0020] "API Base Oil Category" refers to the classification of base oils that conform to the different standards shown in Table 1: [surface] [1]: Properties of base oil feedstock (feedstock with a viscosity of 4 cSt at 100℃, without additives) Group Name composition Sulfur, weight % Saturated hydrocarbons, % by weight Viscosity index, VI volatility,% polarity Pour point, ℃ Flash point, ℃ Class I Distillation, solvent refining, ≥10% aromatics >0.03 and / or <90 80-119 15-20 Medium and high -5 to 15 100 Category II Distillation, solvent refining, hydrocracking, <10% aromatics ≤0.03 and ≥90 80-119 10-15 middle -10 to -20 170 Category III Distillation, solvent refining, heavy hydrocracking, <10% aromatics ≤0.03 and ≥90 ≥120 5-15 middle -10 to 25 190 Class III+ Group III oils, after further hydroisomerization or other treatments, contain <1% aromatics. -- -- ≥130 ≤5 Low -15 to -30 200 Class IV Polyalphaolefin (PAO) is 100% synthesized by catalytic synthesis from olefins derived from thermally cracked waxes. -- -- 135-140 1.8 Low -53 270 Category V 100% synthesized via acid-alcohol catalytic reaction; all base oils are excluded from Groups I-IV. -- -- 140 1.0 high -twenty one 260

[0021] "API specific gravity" refers to the specific gravity of petroleum feedstocks or products relative to water, determined by ASTM D4052-11 or ASTM D1298, and is usually performed using commercially available petroleum analysis equipment.

[0022] "ISO-VG" refers to the viscosity classification recommended for industrial applications, as defined by ISO 3448:1992.

[0023] "Viscosity index" (VI) indicates the temperature dependence of a lubricant, as determined by ASTM D2270-10 (E2011), and is usually performed using commercially available petroleum analysis equipment.

[0024] "Microcarbon Residue" (MCRT) refers to the amount of carbon residue formed as determined by ASTM D4530, typically performed using commercially available petroleum analysis equipment.

[0025] "Aromatic extraction" is part of a process used to produce solvent-neutral base oils. During aromatic extraction, a solvent is used in a solvent extraction unit to extract vacuum gasified oil, deasphalted oil, or mixtures thereof. Aromatic extraction produces a waxy extract residue and aromatic extract after the solvent evaporates.

[0026] "Ambient oil residue" or "atmospheric residual oil" (AR) is the product of crude oil distillation at atmospheric pressure, in which volatile materials are removed during distillation. AR fractions are typically produced at fractionation points from 650℉ to 680℉.

[0027] "Vacuum-generated gas oil" (VGO) is a byproduct of crude oil vacuum distillation, which can be sent to a hydrogenation unit or aromatics extraction unit to be upgraded to base oil. VGO typically contains hydrocarbons with a boiling range between 343°C (649°F) and 538°C (1000°F) at 0.101 MPa. As used herein, the term "medium-grade vacuum-generated gas oil" (MVGO) refers to vacuum-generated gas oil or a portion thereof, including, for example, vacuum-generated gas oil or a portion thereof where the front-end fraction has a boiling point of about 700°F or higher and the rear-end fraction has a boiling point of about 900°F or lower. The term "heavy-grade vacuum-generated gas oil" (HVGO) refers to heavy-grade vacuum-generated gas oil or a portion thereof, including, for example, fractions derived from VGO. In some cases, HVGO can be derived from VGO feedstock where the MVGO fraction has been separated from the VGO feedstock, leaving the remainder as the HVGO fraction. For example, heavy vacuum gas generator oil (HVGO) can be the residue obtained from VGO feedstock, in which the MVGO portion has been removed, and the MVGO portion has a front fractionation point of about 700℉ or higher and a back fractionation point of about 900℉ or lower.

[0028] "Deasphalted oil" (DAO) generally refers to residual oil from a vacuum distillation unit that has been deasphalted in a solvent deasphalting process. Solvent deasphalting in refineries is described in J. Speight's Synthetic Fuels Handbook (ISBN 007149023Χ, 2008, pp. 64, 85-85 and 121).

[0029] When used in conjunction with oil feedstocks, “processed,” “treated,” “upgraded,” “enhanced,” and “enhanced” describe feedstocks that are being or have been hydrogenated, or the resulting materials or crude oil products that have the following characteristics: a decrease in the molecular weight of the feedstock, a narrowing of the boiling point range of the feedstock, a decrease in the concentration of asphaltene, a decrease in the concentration of hydrocarbon free radicals, and / or a reduction in the amount of impurities such as sulfur, nitrogen, oxygen, halides, and metals.

[0030] Solvent dewaxing is a process that removes wax from paraffin by crystallizing and filtering it at low temperatures. Solvent dewaxing produces dewaxed oil and pine wax. The dewaxed oil can be further hydrorefined to produce base oils.

[0031] "Hydrolysis" refers to the process of contacting carbonaceous feedstocks with hydrogen and a catalyst at higher temperatures and pressures to remove unwanted impurities and / or convert the feedstocks into desired products. Examples of hydrolysis processes include hydrocracking, hydrotreating, catalytic dewaxing, and hydrorefining.

[0032] "Hydrocracking" refers to the process of hydrogenation and dehydrogenation accompanied by the cracking / fragmentation of hydrocarbons, such as converting heavier hydrocarbons into lighter hydrocarbons, or converting aromatics and / or cycloalkanes (cycloalkanes) into acyclic branched alkanes.

[0033] "Hydrotreatment" refers to the process of converting sulfur- and / or nitrogen-containing hydrocarbon feedstock into hydrocarbon products with reduced sulfur and / or nitrogen content. It is usually combined with hydrocracking, and the process produces hydrogen sulfide and / or ammonia (respectively) as byproducts.

[0034] "Catalytic dewaxing" or hydroisomerization refers to the process by which n-alkanes are isomerized into their more branched counterparts in the presence of hydrogen and on a catalyst.

[0035] "Hydrorefining" refers to a process intended to improve the oxidative stability, UV stability, and appearance of a hydrorefined product by removing trace amounts of aromatics, alkenes, chromophores, and solvents. As used in this disclosure, the term UV stability refers to the stability of the tested hydrocarbon when exposed to UV light and oxygen. The formation of visible precipitates indicates instability, which is generally considered as HOC or turbidity, or the appearance of a deeper color upon exposure to UV light and air. A general description of hydrorefining can be found in U.S. Patents 3,852,207 and 4,673,487.

[0036] The term "hydrogen" or "hydrogen gas" refers to hydrogen itself, and / or one or more compounds that provide a source of hydrogen.

[0037] "Fracturing point" refers to the temperature at which the desired degree of separation is achieved on the true boiling point (TBP) curve.

[0038] "TBP" refers to the boiling point of hydrocarbon feedstock or product, as determined by simulated distillation (SimDist) according to ASTM D2887-13.

[0039] "Hydrocarbon," "hydrocarbon," and similar terms refer to compounds containing only carbon and hydrogen atoms. Other identifiers may be used to indicate the presence (if present) of a specific group in a hydrocarbon (e.g., halohydrocarbons indicate the presence of one or more halogen atoms replacing an equal amount of hydrogen atoms in the hydrocarbon).

[0040] "Group IIB" or "Group IIB metals" refers to zinc (Zn), cadmium (Cd), mercury (Hg), and combinations thereof, in elemental, compound, or ionic form.

[0041] "Group IVA" or "Group IVA metals" refers to germanium (Ge), tin (Sn), or lead (Pb) and combinations thereof in elemental, compound, or ionic form.

[0042] "Group V metals" refers to vanadium (V), niobium (Nb), tantalum (Ta), and combinations thereof, in elemental, compound, or ionic form.

[0043] "Group VIB" or "Group VIB metals" refers to chromium (Cr), molybdenum (Mo), tungsten (W) and combinations thereof in elemental, compound or ionic form.

[0044] "Group VIII" or "Group VIII metals" refers to iron (Fe), cobalt (Co), nickel (Ni), ruthenium (Ru), rhenium (Rh), rhodium (Ro), palladium (Pd), osmium (Os), iridium (Ir), platinum (Pt), and combinations thereof, in elemental, compound, or ionic form.

[0045] The term "support," particularly when used in the term "catalyst support," refers to a known material, typically a solid with a high surface area, on which the catalyst material is attached. Support materials can be inert or participate in the catalytic reaction, and can be porous or non-porous. Typical catalyst supports include various carbons, alumina, silica, and silica-alumina, such as amorphous silica aluminates, zeolites, alumina-boron oxide, silica-alumina-magnesium oxide, silica-alumina-titanium oxide, and materials obtained by adding other zeolites and other complex oxides.

[0046] "Molecular sieve" refers to a material with uniform pores of molecular size within a framework structure. Depending on the type of molecular sieve, only certain molecules can approach the pore structure, while other molecules are excluded, for example, due to molecular size and / or reactivity. Zeolites, crystalline aluminophosphates, and crystalline silica aluminophosphates are representative examples of molecular sieves.

[0047] W220 and W600 refer to waxy medium and heavy Group II base oil product grades. W220 refers to a waxy medium base oil product with a nominal viscosity of approximately 6 cSt at 100°C, and W600 refers to a waxy heavy base oil product with a nominal viscosity of approximately 12 cSt at 100°C. Typical test data for Group II base oils after dewaxing are as follows: [nature] [Standard Test] [220N] [600N] API Base Oil Categories (API 1509 E.1.3) Category II Category II API weight ASTM D1298 32.1 31.0 Specific gravity at 60 / 60℉ ASTM D1298 0.865 0.871 Density, pounds / gal ASTM D1298 7.202 7.251 Kinematic viscosity, cSt at 40℃ cSt at 100℃ ASTM D445 41.0 6.3 106 12.0 Viscosity at 100℉, Sayco SUS ASTM D2161 212 530 Viscosity Index ASTM D2270 102 102 Pour point, ℃ ASTM D97 -15 -15 Evaporation loss, NOACK, weight % CEC-L-40-A-93 11 2 Flash point, COC, ℃ ASTM D92 230 265 color ASTM D1500 L 0.5 L 0.5 Sulfur, ppm Chevron <6 <6 water,ppm ASTM D1744 <50 <50 saturated hydrocarbons, HPLC, wt% Chevron >99 >99 Aromatics, HPLC, wt% Chevron <1 <1

[0048] In this disclosure, although compositions and methods or processes are generally described as "comprising" various components or steps, unless otherwise stated, compositions and methods may also be "substantially composed of various components or steps" or "composed of various components or steps".

[0049] The terms “a”, “an”, and “the” are intended to include a plurality of alternatives, such as at least one. For example, unless otherwise specified, the disclosure of “transition metal” or “alkali metal” is intended to cover one or more of the transition metals or alkali metals, or a mixture or combination of more than one transition metal or alkali metal.

[0050] All numerical values ​​in the embodiments and claims described herein are modified by the meaning of “about” or “approximately”, and take into account experimental errors and variations expected by those skilled in the art.

[0051] In one embodiment, the present invention relates to a process for manufacturing a bright, lubricating oil base oil with a viscosity of at least about 22 cSt at 100°C. The process comprises: contacting a base oil feed stream containing atmospheric residual oil feedstock and, where appropriate, base oil feedstock, with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracking product; separating the hydrocracking product into a gaseous fraction and a liquid fraction; contacting the liquid fraction with a dewaxing catalyst under hydroisomerization conditions to produce a dewaxing product; and, where appropriate, contacting the dewaxing product with a hydrorefining catalyst under hydrorefining conditions to produce a hydrorefined dewaxing product; wherein the process produces a bright, lubricating oil base oil product with a viscosity of at least about 22 cSt at 100°C.

[0052] This base oil feedstock typically meets one or more of the following properties: The API specific gravity is in the range of 15-40, 15-30, or 15-25, or at least 15 or at least 17, and may be less than that of the atmospheric pressure residual oil feedstock, depending on the circumstances. The VI value is within the range of 30-90, 40-90, 50-90, or 50-80, and may be less than the VI value of the atmospheric pressure residual oil feedstock, depending on the circumstances. Viscosity at 100°C is in the range of 3-30 cSt or 3-25 cSt or 3-20 cSt, or at least 3 cSt or at least 4 cSt; Viscosity at 70°C is in the range of 5-50 cSt or 5-80 wt% or 5-70 wt% or 5-60 wt% or 5-50 wt% or 5-40 wt% or 5-30 wt% or 5-20 cSt or 5-15 cSt, or at least 5 cSt or at least 6 cSt; The thermal C7 asphaltene content is in the range of 0.01-0.3% by weight, 0.01-0.2% by weight, or 0.02-0.15% by weight, or less than 0.3% by weight or less than 0.2% by weight; The wax content is in the range of 5-90% by weight, 5-80% by weight, 5-70% by weight, 5-60% by weight, 5-50% by weight, 5-40% by weight, 5-30% by weight, or 10-25% by weight, or at least 5% by weight, at least 10% by weight, or at least 15% by weight, or, as appropriate, less than the wax content of the atmospheric residual oil feedstock; Nitrogen content less than 2500 ppm, less than 2000 ppm, less than 1500 ppm, less than 1000 ppm, or within the range of 1000-5000 ppm, 2000-5000 ppm, 1000-4000 ppm, or 1000-3000 ppm; Sulfur content less than 40,000 ppm, or less than 35,000 ppm, or less than 30,000 ppm, or less than 25,000 ppm, or less than 20,000 ppm, or less than 15,000 ppm, or less than 10,000 ppm, or within the range of 1,000-40,000 ppm, 1,000-35,000 ppm, 1,000-30,000 ppm, 1,000-25,000 ppm, 1,000-15,000 ppm, or 1,000-10,000 ppm; and / or The content of 1050+℉ is less than 10% by weight, or less than 8% by weight, or less than 7% by weight, or less than 6% by weight, or less than 5% by weight, or less than 4% by weight, or less than 3% by weight, or less than 2% by weight, or within the range of 2-15% by weight, or 2-10% by weight, or 1-7% by weight, depending on the circumstances, less than the 1050+℉ content of the atmospheric pressure residual oil raw material.

[0053] In some samples, the base oil feedstock has the following characteristics: nitrogen content less than 2500 ppm, less than 2000 ppm, less than 1500 ppm, less than 1000 ppm, or in the range of 1000-5000 ppm, 2000-5000 ppm, 1000-4000 ppm, or 1000-3000 ppm; or sulfur content less than 40000 ppm, less than 35000 ppm, less than 30000 ppm, less than 25000 ppm, less than 20000 ppm, less than 15000 ppm, or less than 10000 ppm, or in the range of 1000-40000 ppm, 1000-35000 ppm, 1000-30000 ppm, 1000-25000 ppm, 1000-15000 ppm, or 1000-10000 ppm. Within the range of ppm; or the content of 1050+℉ is less than 10 wt%, or less than 8 wt%, or less than 7 wt%, or less than 6 wt%, or less than 5 wt%, or less than 4 wt%, or less than 3 wt%, or less than 2 wt%, or within the range of 2-15 wt%, or 2-10 wt%, or 1-7 wt%, depending on the circumstances, less than the 1050+℉ content of the atmospheric pressure residual oil feedstock; or a combination thereof.

[0054] Suitable base oil feedstocks can be derived from any crude oil feedstock or its fractions, including hydrotreated intermediate streams or other feeds. Typically, base oil feedstocks contain materials with boiling points within the base oil range. Feedstocks can include atmospheric and vacuum residues from a variety of sources, including whole crude oil and paraffinic crude oil.

[0055] Atmospheric residual oil (AR) feedstock typically meets one or more of the following properties: The API specific gravity is in the range of 20-60, 20-45, or 25-45, or at least 20 or at least 22, or, as appropriate, greater than the API of the base oil feedstock; The VI is in the range of 50-200, 70-190, or 90-180, or at least 80, or, as appropriate, greater than the VI of the base oil feedstock; The viscosity at 100°C is in the range of 3-30 cSt, 3-25 cSt, 3-20 cSt, or 3-10 cSt, or at least 3 cSt or at least 4 cSt, or less than 10 cSt; The viscosity at 70°C is in the range of 5-50 cSt, 5-30 cSt, 5-20 cSt, or 5-15 cSt, or at least 5 cSt or at least 6 cSt; The thermal C7 asphaltenes content is in the range of about 0.01-0.3% by weight, or about 0.01-0.2% by weight, or about 0.02-0.15% by weight, or less than about 0.3% by weight, or less than about 0.2% by weight, or less than about 0.1% by weight; The wax content is in the range of 5-90% by weight, or 5-80% by weight, or 5-70% by weight, or 5-60% by weight, or 5-50% by weight, or 5-40% by weight, or 5-30% by weight, or 10-25% by weight, or at least 5% by weight, or at least 10% by weight, or at least 15% by weight, or, as appropriate, greater than the wax content of the base oil feedstock; Nitrogen content less than 2500 ppm, or less than 2000 ppm, or less than 1500 ppm, or less than 1000 ppm, or less than 800 ppm, or less than 500 ppm, or less than 200 ppm, or less than 100 ppm; Sulfur content less than 8000 ppm, or less than 6000 ppm, or less than 4000 ppm, or less than 3000 ppm, or less than 2000 ppm, or less than 1000 ppm, or less than 500 ppm, or less than 200 ppm, or within the range of 100-8000 ppm, or 100-6000 ppm, or 100-4000 ppm, or 100-2000 ppm, or 100-1000 ppm, or 100-500 ppm, or 100-200 ppm; and / or The 1050+℉ content is in the range of 2-50 wt%, 2-40 wt%, or 4-50 wt%, or 4-40 wt%, or 8-50 wt%, or 8-40 wt%, or at most 50 wt%, or at most 40 wt%, or at most 30 wt%, or at most 20 wt%, or at most 10 wt%, and may be greater than the 1050+℉ content of the base oil feedstock, as appropriate.

[0056] In some phenotypes, AR feedstocks possessing the properties described herein can be advantageously derived from light tight oil (LTO, e.g., shale oil with an API value typically >45). Suitable feedstocks include Permian basin feedstocks and other locations, including Eagle Ford, Avalon, Magellan, Buckeye, and similar sites.

[0057] Atmospheric residual oil (AR) feedstock typically differs from conventional AR feedstock. For example, AR feedstock typically differs from conventional AR feedstock in one or more of the aforementioned feedstock properties, and the AR feedstock used in this invention generally has lower property values ​​and ranges. In more specific cases, compared to conventional AR, AR feedstock has lower thermal C7 asphaltenes content, nitrogen and / or sulfur content, 1050+℉ content, metal content (e.g., nickel, vanadium, and / or iron) or combinations thereof.

[0058] In some cases, atmospheric residual oil feedstock has the following characteristics: the hot C7 asphaltene content is less than about 0.3% by weight, less than about 0.2% by weight, or less than about 0.1% by weight; and the nitrogen content is less than 2500 ppm, less than 2000 ppm, less than 1500 ppm, less than 1000 ppm, less than 800 ppm, less than 500 ppm, less than 200 ppm, or less than 100 ppm. The atmospheric residual oil feedstock may also have the following characteristics: a thermal C7 asphaltene content of less than about 0.3% by weight, less than about 0.2% by weight, or less than about 0.1% by weight; a nitrogen content of less than 2500 ppm, less than 2000 ppm, less than 1500 ppm, less than 1000 ppm, less than 800 ppm, less than 500 ppm, less than 200 ppm, or less than 100 ppm; and a metal content of less than about 5 ppm of nickel, less than about 3 ppm of vanadium, or less than about 4 ppm of iron; or a combination thereof. Furthermore, AR feedstocks can also meet the following conditions: atmospheric residual oil feedstocks should meet the following conditions: viscosity at 100°C less than 10 cSt, or in the range of 3-10 cSt; hot C7 asphaltene content less than about 0.1% by weight, or in the range of about 0.01-0.1% by weight; MCRT less than 2% by weight; nitrogen content less than 800 ppm; sulfur content less than ppm; nickel content less than 5 ppm; vanadium content less than 3 ppm; and iron content less than 4 ppm.

[0059] Both base oil feedstock and atmospheric residual oil feedstock may have any of the prior properties within any of the above-mentioned broad range, narrower range, and combinations thereof.

[0060] The base oil feed stream typically contains 5-95 wt% atmospheric residual oil feedstock and 95-5 wt% base oil feedstock, or 10-90 wt% atmospheric residual oil feedstock and 90-10 wt% base oil feedstock, or 10-80 wt% atmospheric residual oil feedstock and 90-20 wt% base oil feedstock, or 10-60 wt% atmospheric residual oil feedstock and 90-40 wt% base oil feedstock, or 10-50 wt% atmospheric residual oil feedstock and 50-90 wt% base oil feedstock, or 10-40 wt% atmospheric residual oil feedstock and 90-60 wt% base oil feedstock, or 10-30 wt% atmospheric residual oil feedstock and 90-70 wt% base oil feedstock, or 30-60 wt% atmospheric residual oil feedstock and 70-40 wt% base oil feedstock, or 40-60 wt% atmospheric residual oil feedstock and 60-40 wt% base oil feedstock.

[0061] In some embodiments, the base oil feed stream contains no added whole crude oil feedstock, and / or no vacuum residual feedstock, and / or no deasphalted oil feedstock components, and / or contains only atmospheric residual feedstock and base oil feedstock. While some specific properties of the base oil feedstock and AR feedstock may have similar or overlapping property values ​​or ranges, the base oil feedstock and AR feedstock are not identical, as typically one or more properties will be significantly different. For example, in some cases, the atmospheric residual feedstock and base oil feedstock differ in their respective nitrogen content, sulfur content, 1050+℉ content, or combinations thereof.

[0062] While not limited to straight-run processes, the process does not need to include recycling liquid feedstock as part of the base oil feed stream or as either or both of atmospheric residue feedstock and base oil feedstock. However, in some embodiments, the recycling of one or more intermediate streams may be used.

[0063] The base oil feedstock may contain, or be substantially composed of, vacuum-generated gas (VGO), including whole uncut feedstock and cut feedstock. The VGO may be a heavy VGO obtained from the fractionation of light and heavy fractions, wherein the heavy fraction has a fractionation point temperature range of approximately 950-1050℉. VGO may also be a blend derived from various feedstocks and may include different amounts of components with defined boiling point ranges. For example, one component of VGO derived from a specific feedstock may have a higher 1050+℉ content, while other VGO components contribute a lower 1050+℉ content to the VGO.

[0064] Typically, dewaxing products and / or hydrorefining dewaxing products are obtained as light base oil products and heavy base oil products. The nominal viscosity of the light base oil products at 100°C is typically in the range of about 3-9 cSt, 4-8 cSt, or 5-7 cSt, and / or the nominal viscosity of the heavy base oil products at 100°C is typically in the range of 13-24 cSt, 13-21 cSt, or 13-18 cSt. The dewaxing products can be further separated into at least one light product with a nominal viscosity of about 6 cSt at 100°C, and / or at least one heavy product with a nominal viscosity of 13 cSt or higher at 100°C, or 13-16.5 cSt at 100°C, or about 13-23 cSt at 100°C, or combinations thereof.

[0065] Compared to the same process that excludes atmospheric residual oil feedstock in the lubricating oil feedstream, one of the advantages associated with this process is that the yield of heavy base oil product relative to light base oil product can be increased by at least about 0.5 liquid volume % (L vol.%), or at least about 1 L vol.%, or at least about 2 L vol.%, or at least about 5 L vol.%. In some embodiments, compared to the same process that excludes atmospheric residual oil feedstock in the base oil feedstream, the yield of heavy base oil product can be increased by at least about 0.5 L vol.%, or at least about 1 L vol.%, or at least about 2 L vol.%, or at least about 5 L vol.%, or at least about 10 L vol.%, or at least about 20 L vol.%. The total wax content yield can also be increased by at least about 0.5 L vol.%, or at least about 1 L vol.%, or at least about 2 L vol.%, or at least about 5 L vol.%.

[0066] In another embodiment, the present invention relates to a method for modifying a conventional or existing base oil process to produce a bright, slippery oil base oil product with a viscosity of at least about 22 cSt at 100°C. Specifically, a base oil process comprising subjecting a base oil feed stream to a hydrocracking step and a dewaxing step to form a dewaxed product comprising both lighter and heavier products can be modified according to the invention by subjecting a base oil feedstock comprising atmospheric residual oil feedstock to a hydrocracking step and a dewaxing step of the base oil process to produce a dewaxed product. The dewaxed product may, if appropriate, be further contacted with a hydrorefining catalyst under hydrorefining conditions to produce a hydrorefined dewaxed product comprising a bright, slippery oil product.

[0067] The present invention further relates to a process for producing a bright lubricating oil base oil with a viscosity of at least about 22 cSt at 100°C from a base oil feed stream or its fractions. The process comprises: providing a base oil feed stream containing atmospheric residual oil feedstock and, where appropriate, base oil feedstock; separating the base oil feed stream into vacuum gasified oil fractions with a front-end fractionation point of about 700°F or higher and a rear-end fractionation point of about 900°F or lower, to form a medium vacuum gasified oil (MVGO) fraction and a heavy vacuum gasified oil (HVGO) fraction; contacting the HVGO fraction with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracking product; separating the hydrocracking product into a gas fraction and a liquid fraction; dewaxing the liquid fraction to produce a dewaxed product; and, where appropriate, hydrorefining the dewaxed product to produce a hydrorefined dewaxed product, such that the process produces at least one bright lubricating oil base oil product with a viscosity of at least about 22 cSt at 100°C.

[0068] Compared to using conventional VGO feedstock, vacuum gasification oil (MVGO), referred to herein as medium-quality vacuum gasification oil, provides a modified waxy product yield of MVGO at Group III or III+ viscosity at 4 cSt 100°C, with a front-end fractionation point of about 700°F or higher and a rear-end fractionation point of about 900°F or lower. This yield is at least about 0.5 l vol.%, or 1 l vol.%, or 2 l vol.%, or 3 l vol.%, or 5 l vol.%, greater than that of the same process excluding MVGO as a base oil feedstock.

[0069] The present invention further relates to a process that combines two process states, namely, one feedstock is used to derive a narrow-fraction MVGO fraction and the same or different feedstocks are used for an atmospheric residual oil fraction. A combined process for manufacturing base oils including bright and slippery oils from base oil feedstocks or their fractions includes: providing an atmospheric residual oil fraction from a base oil feedstock or its fractions; separating the base oil feedstock or its fractions and / or the atmospheric residual oil fraction into narrow vacuum gasification oil fractions with a front-end fractionation point of about 700℉ or higher and a rear-end fractionation point of about 900℉ or lower to form an MVGO fraction and a residual HVGO fraction; using the HVGO fraction as an atmospheric residual oil feedstock in a first process to prepare dewaxed products and / or hydrorefined dewaxed products; and / or using the MVGO fraction as a base oil feedstock in a second process to prepare dewaxed products with a viscosity index of 120 or higher after dewaxing and / or hydrorefined dewaxed products, while also producing at least one bright and slippery oil base oil product with a viscosity of at least about 22 cSt at 100°C.

[0070] In some embodiments, the base oil feedstock may comprise tight oil, particularly light tight oil, or a fraction thereof. Narrow vacuum gasification oil fractions may also be derived from atmospheric residue fractions, including atmospheric residue fractions derived from light tight oil.

[0071] Advantageously, fractionating AR feedstock into MVGO and HVGO fractions provides the capability to produce Group III / III+ base oil products, while still allowing the HVGO fraction to be used with conventional VGO base oil feedstocks to produce heavy-grade base oil products, particularly bright and slip base oil products with a viscosity of at least about 22 cSt at 100°C. For example, the Group III / III+ products that can be produced include base oil products with a viscosity of about 4 cSt at 100°C (e.g., 3-5 cSt at 100°C). In some embodiments, using MVGO to produce Group III / III+ base oil products results in higher yields of such products.

[0072] Figure 2a schematically illustrates a method or process according to one embodiment of the present invention, wherein conventional base oil hydrotreating, hydrocracking, hydrodewaxing, and hydrorefining procedures, conditions, and catalysts are used. Compared to the prior art base oil process schematic shown in Figure 1, Figure 2a illustrates the use of a feed blend of VGO and atmospheric residue (AR), wherein conventional processes typically use VGO base oil feedstock. Figure 2b further illustrates the use of AR feedstock to form a medium vacuum gasification oil fraction (MVGO) and a heavy VGO fraction (HVGO). The MVGO feedstream is used to produce Group III / III+ base oil products, while the HVGO feedstream is combined with conventional VGO base oil feedstock to produce heavy base oil products, such as products containing bright and slip base oils.

[0073] Catalysts suitable for use as catalysts in hydrocracking, dewaxing, and hydrorefining processes and methods are described in numerous publications, including, for example, U.S. Patent Publications 3,852,207; 3,929,616; 6,156,695; 6,162,350; 6,274,530; 6,299,760; 6,566,296; 6,620,313; 6,635,599; 6,652,738; 6,758,963; 6,783,663; 6,86 Nos. 0,987; 7,179,366; 7,229,548; 7,232,515; 7,288,182; 7,544,285; 7,615,196; 7,803,735; 7,807,599; 7,816,298; 7,838,696; 7,910,761; 7,931,799; 7,964,524; 7,964,525; 7,964,526; 8,058,203; 10,196,575; WO 2017 / 044210; and others. Suitable catalysts typically include supported catalysts, i.e., catalysts comprising one or more supports as described herein and known in the art. For example, unsupported or bulk catalysts of mixed metal sulfide catalysts, as described in US 2015 / 136646, are generally not required in this process.

[0074] Catalysts suitable for hydrocracking include materials with hydrocracking-dehydrogenation activity and active pyrolysis component supports. Such catalysts are described in detail in numerous patents and literature references. Exemplary pyrolysis component supports include silica-alumina, silica-zirconia composites, acid-treated clay, crystalline aluminosilicate zeolite molecular sieves (such as zeolite A, octahedral zeolite, zeolite X, and zeolite Y), and combinations thereof. The hydrocracking-dehydrogenation component of the catalyst preferably comprises a metal selected from Group VIII metals and their compounds, and Group VIB metals and their compounds. Preferred Group VIII components include cobalt and nickel, particularly their oxides and sulfides. Preferred Group VIB components are oxides and sulfides of molybdenum and tungsten. Examples of hydrocracking catalysts suitable for use in hydrocracking process steps are combinations of nickel-tungsten-silica-alumina, nickel-molybdenum-silica-alumina, and cobalt-molybdenum-silica-alumina. The hydrogenation and cracking activity of such catalysts, as well as their ability to maintain high activity during long-term use, depends on their composition and preparation.

[0075] Typical hydrocracking reaction conditions include, for example: temperature: 450℉ to 900℉ (232℃ to 482℃), e.g., 650℉ to 850℉ (343℃ to 454℃); pressure: 500 psig to 5000 psig (3.5 MPa to 34.5 MPa gauge pressure), e.g., 1500 psig to 3500 psig (10.4 MPa to 24.2 MPa gauge pressure); liquid reactant feed rate in liquid space-time velocity (LHSV): 0.1 hr⁻¹ to 15 hr⁻¹ (v / v), e.g., 0.25 hr⁻¹ to 2.5 hr⁻¹; hydrogen feed rate in H₂ / hydrocarbon ratio: 500 SCF / bbl to 5000 SCF / bbl of liquid base oil (lubricating) feedstock (89 to 890 m³ H₂ / m³ feedstock); and / or hydrogen partial pressure: greater than 200 psig, such as 500 to 3000 psig; and hydrogen recirculation rate: greater than 500 SCF / B, such as between 1000 SCF / B and 7000 SCF / B.

[0076] Hydrodewaxing is primarily used to lower the pour point and / or cloud point of base oils by removing wax from them. Typically, dewaxing uses a catalytic process to treat the wax; the dewaxer feed is usually upgraded before dewaxing to increase the viscosity index, reduce the content of aromatics and heteroatoms, and decrease the amount of low-boiling components in the dewaxer feed. Some dewaxing catalysts complete the wax conversion reaction by breaking down wax-containing molecules into lower molecular weight molecules. Other dewaxing processes can convert the wax contained in the hydrocarbon feed of the process into isomerized molecules with a pour point lower than the non-isomerized molecule counterpart, through wax isomerization. As used herein, isomerization encompasses the hydroisomerization process, which uses hydrogen in the isomerization of wax molecules under catalytic hydroisomerization conditions.

[0077] Dewaxing typically involves treating the dewaxing feedstock with hydroisomerization to at least convert n-alkanes and form isomerized products containing isoalkanes. Suitable isomerization catalysts used in the dewaxing step may include, but are not limited to, Pt and / or Pd on a support. Suitable supports include, but are not limited to, zeolites CIT-1, IM-5, SSZ-20, SSZ-23, SSZ-24, SSZ-25, SSZ-26, SSZ-31, SSZ-32, SSZ-32, SSZ-33, SSZ-35, SSZ-36, SSZ-37, SSZ-41, SSZ-42, SSZ-43, S SZ-44, SSZ-46, SSZ-47, SSZ-48, SSZ-51, SSZ-56, SSZ-57, SSZ-58, SSZ-59, SSZ-60, SSZ-61, SSZ-63, SSZ-64, SSZ-65, SSZ-67, SSZ-68, SSZ-69, SSZ-70, SSZ-71 SSZ-74, SSZ-75, SSZ-76, SSZ-78, SSZ-81, SSZ-82, SSZ-83, SSZ-86, SSZ-91, SSZ-95, SUZ-4, TNU-9, ZSM-S, ZSM-12, ZSM-22, ZSM-23, ZSM-35, ZSM-48, EMT type zeolite, FAU type zeolite, FER type zeolite, MEL type zeolite, MFI type zeolite, MTT type zeolite, MTW type zeolite, MWW type zeolite, MRE type zeolite, TON type zeolite, and other molecular sieve materials based on crystalline aluminum phosphate, such as SM-3, SM-7, SAPO-11, SAPO-31, SAPO-41, MAPO-11, and MAPO-31. Isomerization can also involve Pt and / or Pd catalysts supported on acidic support materials such as β or zeolite Y molecular sieves, silica, alumina, silica-alumina, and combinations thereof. Suitable isomerization catalysts are described in detail in the patent literature, see, for example, U.S. Patents 4,859,312; 5,158,665; and 5,300,210.

[0078] Hydrodewaxing conditions typically depend on the feedstock, catalyst, catalyst pretreatment, desired yield, and the desired properties of the base oil. Typical conditions include the following: temperatures of 500℉ to 775℉ (260°C to 413°C); pressures of 15 psig to 3000 psig (0.10 MPa to 20.68 MPa gauge pressure); LHSVs of 0.25 hr⁻¹ to 20 hr⁻¹; and hydrogen-to-feed ratios of 2000 SCF / bbl to 30,000 SCF / bbl (356 to 5340 m³H² / m³ feed). Typically, hydrogen is separated from the product and recycled to the isomerization zone. Suitable dewaxing conditions and procedures are described, for example, in U.S. Patents 5,135,638, 5,282,958, and 7,282,134.

[0079] Waxed products W220 and W600 can be dewaxed to form neutral products 220N and 600N, which are suitable (or more suitable) for use as lubricating base oils or in lubricant formulations. For example, dewaxed products can be mixed or blended with existing lubricating base oils to create new base oils or modify the properties of existing base oils, for example, to meet specific target conditions for specific base oil grades such as 220N and 600N, such as viscosity or Noack target conditions. Isomerization and blending can be used to adjust and maintain the pour point and cloud point of base oils at suitable values. n-Alkanes can also be blended with other base oil components prior to catalytic isomerization, including blending n-alkanes with isomerization products. Lubricating base oils produced in the dewaxing step can be processed in a separation step to remove light products. Lubricating base oils can be further processed by distillation, using atmospheric distillation, and, where appropriate, vacuum distillation to produce lubricating base oils.

[0080] Typical hydrotreating conditions vary over a wide range. Generally, the overall LHSV is about 0.25 hr⁻¹ to 10 hr⁻¹ (v / v), or alternatively about 0.5 hr⁻¹ to 1.5 hr⁻¹. Total pressure is 200 psig to 3000 psig, or alternatively about 500 psia to 2500 psia. Hydrogen feed rate, in H₂ / hydrocarbon ratio, is typically 500 SCF / Bbl to 5000 SCF / bbl (89 to 890 m³ H₂ / m³ feed), usually between 1000 SCF / Bbl and 3500 SCF / Bbl. Reaction temperature in the reactor is typically in the range of about 300℉ to about 750℉ (about 150°C to about 400°C), or alternatively about 450℉ to 725℉ (230°C to 385°C).

[0081] In practice, stratified catalyst systems can be used, which include hydrotreating (HDT, HDM, DEMET, etc.), hydrocracking (HCR), hydrodewaxing (HDW), and hydrorefining (HFN) catalysts to produce intermediate and / or finished base oils using single or multi-reactor systems. A typical configuration includes two reactors, with the first reactor containing a stratified catalyst providing DEMET, HDT pretreatment, HCR, and / or HDW activity. Different catalysts performing similar functions with varying levels of hydrocracking activity can also be used, for example, in different layers within a single reactor or in multiple separate reactors.

[0082] For the avoidance of doubt, this application relates to the subject matter described in the following numbered paragraphs: 1. A process for manufacturing a bright, slippery base oil, the process comprising: Under hydrocracking conditions, a base oil feed stream containing atmospheric residual oil feedstock and, where appropriate, base oil feedstock, is contacted with a hydrocracking catalyst to form hydrocracking products; The hydrocracking products were separated into gaseous and liquid fractions; The liquid fraction is contacted with a dewaxing catalyst under hydroisomerization conditions to produce the dewaxing product; and Depending on the circumstances, the dewaxed product may be contacted with a hydrorefining catalyst under hydrorefining conditions to produce a hydrorefined dewaxed product; The atmospheric residual oil feedstock has an API specific gravity greater than about 25° API, a nickel and vanadium content of less than about 2 ppm, an MCR of less than about 1% by weight, and an asphaltene content of less than about 500 ppm. The process produces a bright lubricating oil base oil product with a viscosity of at least about 22 cSt at 100°C. 2. The method as described in paragraph 1, used to modify a base oil process to produce a bright, slip base oil with a viscosity of at least about 22 cSt at 100°C, wherein the base oil process includes subjecting the base oil feed stream to a hydrocracking step and a dewaxing step to form a dewaxed product comprising light and heavy products; the process includes, The base oil feed stream containing atmospheric residual oil feedstock undergoes the hydrocracking and dewaxing steps of the base oil processing procedure; The modified base oil process includes: Under hydrocracking conditions, a base oil feed stream containing atmospheric residual oil feedstock and, where appropriate, base oil feedstock, is contacted with a hydrocracking catalyst to form hydrocracking products; The hydrocracking product should be separated into at least a gaseous fraction and a liquid fraction; The liquid fraction is contacted with a dewaxing catalyst under hydroisomerization conditions to produce the dewaxing product; and Depending on the circumstances, the dewaxed product may be contacted with a hydrorefining catalyst under hydrorefining conditions to produce a hydrorefined dewaxed product; The modified process produces a bright, lubricating base oil product with a viscosity of at least about 22 cSt at 100°C. 3. A method according to paragraph 1 for producing a bright lubricating oil base oil with a viscosity of at least about 22 cSt at 100°C from a base oil feed stream or its fraction, the process comprising: Provide a base oil feed stream that includes atmospheric residual oil feedstock and, where applicable, base oil feedstock; The base oil feed stream or its fractions are separated into vacuum gasification oil fractions with a front-end fractionation point of approximately 700℉ or higher and a rear-end fractionation point of approximately 900℉ or lower, to form medium vacuum gasification oil (MVGO) fractions and heavy vacuum gasification oil (HHVGO) fractions; and The HHVGO fraction was used as the atmospheric residual oil feedstock in the process of Section 1. 4. The process described in any of paragraphs 1 to 3, wherein the base oil feed stream includes base oil raw materials. 5. For any of the processes described in paragraphs 1 to 4, the atmospheric residual oil feedstock satisfies one or more of the following conditions: The API specific gravity is in the range of 25-60 or 25-45, or, depending on the circumstances, greater than the API of the base oil feedstock; The VI is in the range of 50-200, 70-190, or 90-180, or at least 80, or, as appropriate, greater than the VI of the base oil feedstock; Viscosity at 100°C is in the range of 3-30 cSt, 3-25 cSt, 3-20 cSt, or 3-10 cSt, or at least 3 cSt or at least 4 cSt, or less than 10 cSt; Viscosity at 70°C is in the range of 5-25 cSt, 5-20 cSt, or 5-15 cSt, or at least 5 cSt or at least 6 cSt; The thermal C7 asphaltene content is in the range of 0.01-0.3 wt%, 0.01-0.2 wt%, or 0.02-0.15 wt%, or less than 0.3 wt%, less than 0.2 wt%, or less than 0.1 wt%. The wax content is in the range of 5-40% by weight, 5-30% by weight, or 10-25% by weight, or at least 5% by weight, at least 10% by weight, or at least 15% by weight, or, as appropriate, greater than the wax content of the base oil feedstock; Nitrogen content less than 2500 ppm, or less than 2000 ppm, or less than 1500 ppm, or less than 1000 ppm, or less than 800 ppm, or less than 500 ppm, or less than 200 ppm, or less than 100 ppm; Sulfur content less than 8000 ppm, or less than 6000 ppm, or less than 4000 ppm, or less than 3000 ppm, or less than 2000 ppm, or less than 1000 ppm, or less than 500 ppm, or less than 200 ppm, or within the range of 100-8000 ppm, or 100-6000 ppm, or 100-4000 ppm, or 100-2000 ppm, or 100-1000 ppm, or 100-500 ppm, or 100-200 ppm; and / or The 1050+℉ content is in the range of 5-50% by weight, 2-40% by weight, 4-50% by weight, 4-40% by weight, 8-50% by weight, or 8-40% by weight, or at most 50% by weight, 40% by weight, 30% by weight, 20% by weight, or 10% by weight, and may be greater than the 1050+℉ content of the base oil feedstock, as appropriate. 6. The process described in any of paragraphs 1 to 5, wherein the atmospheric residual oil feedstock has the following characteristics: the hot C7 asphaltene content is less than about 0.3% by weight, less than about 0.2% by weight, or less than about 0.1% by weight; and the nitrogen content is less than 2500 ppm, less than 2000 ppm, less than 1500 ppm, less than 1000 ppm, less than 800 ppm, less than 500 ppm, less than 200 ppm, or less than 100 ppm. 7. The process described in any of paragraphs 1 to 6, wherein the atmospheric residual oil feedstock has the following characteristics: a thermal C7 asphaltene content of less than about 0.3% by weight, less than about 0.2% by weight, or less than about 0.1% by weight; a nitrogen content of less than 2500 ppm, less than 2000 ppm, less than 1500 ppm, less than 1000 ppm, less than 800 ppm, less than 500 ppm, less than 200 ppm, or less than 100 ppm; and a metal content of less than about 5 ppm of nickel, less than about 3 ppm of vanadium, or less than about 4 ppm of iron; or a combination thereof. 8. For any of the processes described in paragraphs 1 to 7, the atmospheric residual oil feedstock shall meet the following conditions: Viscosity at 100℃ is less than 10 cSt, or in the range of 3-10 cSt; The thermal C7 asphaltenes content is less than about 0.1% by weight, or in the range of about 0.01-0.1% by weight; MCRT less than 2% by weight; Nitrogen content less than 800 ppm; Sulfur content less than 3000 ppm; Nickel content less than 5 ppm; Vanadium content less than 3 ppm; and Iron content is less than 4 ppm. 9. For any of the processes described in paragraphs 1 to 8, the base oil feedstock satisfies one or more of the following conditions: The API specific gravity is in the range of 15-40, 15-30, or 15-25, or at least 15 or at least 17, and may be less than that of the atmospheric pressure residual oil feedstock, depending on the circumstances. The VI value is within the range of 30-90, 40-90, 50-90, or 50-80, and may be less than the VI value of the atmospheric pressure residual oil feedstock, depending on the circumstances. Viscosity at 100°C is in the range of 3-30 cSt or 3-25 cSt or 3-20 cSt, or at least 3 cSt or at least 4 cSt; Viscosity at 70°C is in the range of 5-50 cSt or 5-80 wt% or 5-70 wt% or 5-60 wt% or 5-50 wt% or 5-40 wt% or 5-30 wt% or 5-20 cSt or 5-15 cSt, or at least 5 cSt or at least 6 cSt; The thermal C7 asphaltene content is in the range of 0.01-0.3% by weight, 0.01-0.2% by weight, or 0.02-0.15% by weight, or less than 0.3% by weight or less than 0.2% by weight; The wax content is in the range of 5-90% by weight, 5-80% by weight, 5-70% by weight, 5-60% by weight, 5-50% by weight, 5-40% by weight, 5-30% by weight, or 10-25% by weight, or at least 5% by weight, at least 10% by weight, or at least 15% by weight, or, as appropriate, less than the wax content of the atmospheric residual oil feedstock; Nitrogen content less than 2500 ppm, less than 2000 ppm, less than 1500 ppm, or less than 1000 ppm, or within the range of 1000-5000 ppm, 2000-5000 ppm, 1000-4000 ppm, or 1000-3000 ppm; Sulfur content less than 40,000 ppm, or less than 35,000 ppm, or less than 30,000 ppm, or less than 25,000 ppm, or less than 20,000 ppm, or less than 15,000 ppm, or less than 10,000 ppm, or within the range of 1,000-40,000 ppm, 1,000-35,000 ppm, 1,000-30,000 ppm, 1,000-25,000 ppm, 1,000-15,000 ppm, or 1,000-10,000 ppm; and / or The content of 1050+℉ is less than 10% by weight, or less than 8% by weight, or less than 7% by weight, or less than 6% by weight, or less than 5% by weight, or less than 4% by weight, or less than 3% by weight, or less than 2% by weight, or within the range of 2-15% by weight, or 2-10% by weight, or 1-7% by weight, depending on the circumstances, less than the 1050+℉ content of the atmospheric pressure residual oil raw material. 10. The process described in any of paragraphs 1 to 9, wherein the base oil feedstock has each of the following characteristics: nitrogen content less than 2500 ppm, less than 2000 ppm, less than 1500 ppm, or less than 1000 ppm, or in the range of 1000-5000 ppm, 2000-5000 ppm, 1000-4000 ppm, or 1000-3000 ppm; or sulfur content less than 40000 ppm, less than 35000 ppm, less than 30000 ppm, less than 25000 ppm, less than 20000 ppm, less than 15000 ppm, or less than 10000 ppm, or in the range of 1000-40000 ppm, 1000-35000 ppm, 1000-30000 ppm, 1000-25000 ppm, or 1000-15000 ppm. The content of 1050+℉ is less than 10% by weight, less than 8% by weight, less than 7% by weight, less than 6% by weight, less than 5% by weight, less than 4% by weight, less than 3% by weight, or less than 2% by weight, or in the range of 2-15% by weight, 2-10% by weight, or 1-7% by weight, depending on the circumstances, less than the 1050+℉ content of the atmospheric residual oil feedstock; or a combination thereof. 11. The process described in any of paragraphs 1 to 10, wherein the base oil feed stream comprises 5-95% by weight of atmospheric residual oil feedstock and 95-5% by weight of base oil feedstock, or 10-90% by weight of atmospheric residual oil feedstock and 90-10% by weight of base oil feedstock, or 10-80% by weight of atmospheric residual oil feedstock and 90-20% by weight of base oil feedstock, or 10-60% by weight of atmospheric residual oil feedstock and 90-40% by weight of base oil feedstock, or 10- 50% by weight of atmospheric residual oil feedstock and 50-90% by weight of base oil feedstock, or 10-40% by weight of atmospheric residual oil feedstock and 90-60% by weight of base oil feedstock, or 10-30% by weight of atmospheric residual oil feedstock and 90-70% by weight of base oil feedstock, or 30-60% by weight of atmospheric residual oil feedstock and 70-40% by weight of base oil feedstock, or 40-60% by weight of atmospheric residual oil feedstock and 60-40% by weight of base oil feedstock. 12. A process as described in any of paragraphs 1 to 11, wherein the base oil feed stream does not contain any added whole crude oil feedstock, or wherein the base oil feed stream does not contain any vacuum residual oil feedstock, or wherein the base oil feed stream does not contain any deasphalted oil, or wherein the base oil feed stream contains only atmospheric residual oil feedstock and, where appropriate, base oil feedstock. 13. A process as described in any of paragraphs 1 to 12, wherein the process does not include recycling liquid feedstock as part of the base oil feed stream or as either or both of the atmospheric residual oil feedstock and the base oil feedstock. 14. The process described in any of paragraphs 1 to 13, wherein the atmospheric residual oil feedstock is different from the base oil feedstock. 15. As in paragraph 14, the atmospheric residual oil feedstock and the base oil feedstock differ in terms of nitrogen content, sulfur content, 1050+℉ content, or a combination thereof. 16. A process as described in any of paragraphs 1 to 15, wherein the base oil feedstock comprises or is a vacuum-generated oil, or is substantially composed of or is composed of vacuum-generated oil. 17. The process of any one of claims 1 to 16, wherein the vacuum gas-generating oil is a heavy vacuum gas-generating oil obtained by fractionation of vacuum gas-generating oil into light and heavy fractions, wherein the fractionation point temperature range of the heavy fraction is approximately 950-1050℉. 18. The process described in any of paragraphs 1 to 17, wherein the dewaxing product and / or the hydrorefined dewaxing product are obtained as light base oil products and heavy base oil products. 19. As described in paragraph 18, wherein the nominal viscosity of the light base oil product at 100°C is in the range of 3-9 cSt, 4-8 cSt, or 5-7 cSt, and / or the nominal viscosity of the heavy base oil product at 100°C is in the range of 13-24 cSt, 13-21 cSt, or 13-18 cSt. 20. The process described in paragraph 18, wherein, compared to the same process in which the base oil feed stream does not include the atmospheric residual oil feedstock, the yield of the heavy base oil product relative to the light base oil product is increased by at least about 0.5 L vol.% or at least about 1 L vol.% or at least about 2 L vol.% or at least about 5 L vol.%. 21. A process as described in any of paragraphs 18, wherein, compared to the same process in which the base oil feed stream does not include the atmospheric residual oil feedstock, the total waxy base oil yield is increased by at least about 0.5 L vol.% or at least about 1 L vol.% or at least about 2 L vol.% or at least about 5 L vol.%. 22. A process as described in any of paragraphs 1 to 21, wherein the dewaxed product is further separated into at least one lighter product or at least one heavier product or a combination thereof, wherein the nominal viscosity of the at least one lighter product is in the range of about 5.5 to 7.5 cSt at 100°C, and the nominal viscosity of the at least one heavier product is 13 cSt or higher at 100°C, or 13-16.5 cSt at 100°C, or 18-23 cSt at 100°C. 23. As described in paragraph 3, this process further includes The MVGO fraction was contacted with a hydrocracking catalyst under hydrocracking conditions to form hydrocracking products; The hydrocracking products were separated into gaseous and liquid fractions; The liquid fraction is contacted with a dewaxing catalyst under hydroisomerization conditions to produce the dewaxing product; and Depending on the circumstances, the dewaxed product may be contacted with a hydrorefining catalyst under hydrorefining conditions to produce a hydrorefined dewaxed product; The viscosity index of the dewaxed product and / or the hydrorefined dewaxed product is 120 or higher after dewaxing. 24. The process described in paragraph 23, wherein the viscosity index of the dewaxed product and / or the hydrorefined dewaxed product is 130 or higher after dewaxing, or 135 or higher after dewaxing, or 140 or higher after dewaxing. 25. The process described in paragraph 23, wherein the dewaxing product and / or the hydrorefining dewaxing product contains Group III or Group III+ base oil products. 26. The process as described in paragraph 23, wherein the hydrocracking product has a viscosity index of at least about 135 or 140 or 145 or 150. 27. The process of any of paragraphs 1 to 26, wherein the base oil feedstock comprises tight oil or a fraction thereof, and / or the atmospheric residual oil feedstock is derived from tight oil or a fraction thereof. [Example] []

[0083] The vacuum gasified oil (VGO) and atmospheric residual oil (AR) samples were obtained from commercially available sources and used in the process scheme shown in Figure 2a. The AR was fed directly into the base oil hydrocracker, and, if necessary, together with the VGO, without solvent deasphalting pretreatment.

[0084] The process conditions used included a reactor H2 partial pressure of 1700-1800 psia at 0.5 hr - 1 LHSV, a hydrogen feed gasification (recirculation) ratio of approximately 4500 scfb, and a reactor temperature in the range of 700-770+℉. The temperature and other process conditions were selected to produce a light base oil product with a VI of approximately 109 and a viscosity of approximately 6 cSt at 100°C.

[0085] The catalyst loading in each of the reactors shown in Figure 2a is the conventional scheme for base oil production as described above. The catalyst configuration includes a layered catalyst system comprising an alkali metal hydrodemetallization catalyst layer at the top of the reactor catalyst bed, followed by an alkali metal hydrotreatment catalyst, and then an alkali metal hydrocracking catalyst layer with increased activity containing zeolite. [Example] [1] - Vacuum Gas Generating Oil (VGO) Feedstock (Comparative Feedstock)

[0086] A sample of vacuum gasified oil (VGO) feedstock from a commercially available source was obtained and analyzed as a comparative baseline case for the production of base oil products. The VGO feedstock was used in the following examples based on the process configurations shown in Figures 1 and 2a. The properties of this VGO feedstock (sample ID 2358) are shown in Table 1. [surface] [1 -] [Vacuum-generated oil] [(VGO)] [Properties of raw materials] [Feeding] [nature] [VGO] [Property Value] API weight 18 Viscosity index, VI (D2270) 52 Viscosity, 100℃ (cSt) 13.23 Viscosity, 70℃ (cSt) 37.56 Hot C7 asphaltenes (wt%) Wax content (by weight %) 7 Nitrogen content (ppm) 1620 Sulfur content (ppm) 31420 1050+ (by weight) 4.7 Simdist (℉) IBP 525 5% 707 15% 776 20% 795 30% 827 35% 841 40% 855 45% 870 50% 883 55% 897 60% 912 65% 927 70% 941 75% 957 80% 975 85% 994 90% 1016 95% 1048 99% 1099 EP 1116 [Example] [2] - Properties of Atmospheric Residual Oil (AR) Feedstock

[0087] Samples of atmospheric residual oil (AR1 to AR5) from commercially available sources were obtained and analyzed. The properties of these AR samples used as raw material components according to the present invention are shown in Table 2. [surface] [2 -] [Atmospheric pressure residual oil] [(AR)] [Properties of raw materials] [] [Feeding] [nature] [AR] [Sample property values] [AR1] [AR2] [AR3] [AR4] [AR5] Sample ID 2147 2188 2361 2591 2614 API weight 26.6 36.5 28.9 32.6 32.6 Viscosity index, VI (D2270) 108 137 106 134 123 Viscosity, 100℃ (cSt) 13.23 3.843 8.683 6.425 6.511 Viscosity, 70℃ (cSt) 6.957 13.04 13.5 Hot C7 asphaltenes (wt%) 0.12 0.0234 0.0379 Wax content (by weight %) twenty four 14 25 twenty one Nitrogen content (ppm) 808 70.7 623 340 271 Sulfur content (ppm) 5654 805 3938 2266 558 1050+℉ (by weight) 24.2 8.3 15.6 11.9 14.3 Simdist (℉) IBP 439 319 573 431 310 5% 644 477 672 589 543 15% 737 578 722 673 677 20% 766 608 741 699 717 30% 814 666 775 746 774 35% 837 691 792 767 796 40% 860 715 810 785 816 45% 884 737 828 804 836 50% 907 761 849 824 856 55% 931 785 871 845 876 60% 956 809 893 869 896 65% 984 836 918 893 919 70% 1013 865 944 920 942 75% 1045 897 976 948 971 80% 1078 932 1011 982 1003 85% 1116 974 1056 1022 1044 90% 1163 1028 1111 1070 1096 95% 1224 1103 1185 1136 1173 99% 1312 1217 1268 1230 1312 EP 1329 1250 1279 1230 1339

[0088] Table 2A provides a comparative analysis of the properties of conventional AR base oil process feedstock components. It can be noted that the AR shown in Table 2 differs significantly from the AR0 shown in Table 2A. [surface] [2A -] [Representative Commonly Known Residual Oil at Normal Pressure] [(AR)] [Properties of raw materials] [] [Feeding] [nature] [AR0] [sample] [Property Value] API weight 10.7 Viscosity index, VI (D2270) Viscosity, 100℃ (cSt) 123.7 Viscosity, 70℃ (cSt) 2030.5 Hot C7 asphaltenes (wt%) 9.9% Wax content (by weight %) Nitrogen content (ppm) 3492 Sulfur content (ppm) 48262 Nickel (ppm) 43.7 Vanadium (ppm) 180.0 MCRT (weight %) 14.3 [Example] [3] - Properties of blends of atmospheric residual oil (AR) feedstock and vacuum gasified oil (VGO) feedstock

[0089] Samples of atmospheric residual oil AR1 to AR5 from Example 2 were blended with vacuum gasification oil (VGO) feedstock from Example 1 at a weight ratio, and the blends were analyzed. The properties of these AR / VGO blend samples, used as illustrative raw materials according to the present invention, are shown in Table 3. [surface] [3 -] [Atmospheric pressure residual oil] [(AR)] [and vacuum-generated oil] [(VGO)] [Properties of Raw Material Blends] [] [Feeding] [nature] [AR / VGO] [Admixture] [(] [weight] [ / ] [weight] [)] [Sample property values] [45% AR1 / ] [55% VGO] [50% AR2 / ] [50% VGO] [53% AR3 / ] [47% VGO] [20% AR4 / ] [80% VGO] [20% AR5 / ] [80% VGO] [50% AR4 / ] [50% VGO] Sample ID 2148 2190 2394 3924 4122 7200 API weight 20.9 25.9 19.9 19.9 20.6 24.3 Viscosity index, VI (D2270) 73 100 63 72 69 97 Viscosity, 100℃ (cSt) 13.68 6.912 11.99 11.63 11.12 8.783 Viscosity, 70℃ (cSt) 37.28 15.21 32.4 30.59 29.12 20.45 Hot C7 asphaltenes (wt%) 0.0386 Wax content (by weight %) 18 8 15 Nitrogen content (ppm) 1540 1050 1460 1230 1270 991 Sulfur content (ppm) 20490 15630 26160 26620 25880 17430 1050+ (by weight) 6.4 6 6.8 7.3 9.3 Simdist (℉) IBP 633 383 603 568 504 517 5% 702 551 696 693 676 633 10% 750 622 736 737 729 689 15% 781 674 763 765 761 724 20% 804 716 785 786 784 753 25% 823 750 802 804 801 775 30% 840 778 819 820 818 794 35% 856 802 834 835 833 812 40% 871 823 849 850 848 829 45% 885 841 864 865 864 847 50% 899 860 878 880 879 864 55% 915 877 893 895 894 882 60% 930 894 908 910 910 899 65% 944 912 925 927 926 919 70% 960 929 940 942 942 938 75% 978 947 958 960 960 959 80% 999 969 977 979 980 983 85% 1023 992 998 1000 1002 1009 90% 1058 1021 1023 1027 1030 1044 95% 1132 1064 1059 1066 1075 1101 99% 1293 1172 1136 1166 1246 1234 EP 1327 1216 1170 1204 1313 1267 [Example] [4] - Evaluation of the production of bright lubricating oil base oils from a blend of atmospheric residual oil (AR) feedstock and vacuum gasified oil (VGO) feedstock – AR1 / VGO blend

[0090] For the production of heavy base oil according to the process shown in Figure 2a, the atmospheric residual oil AR1 and vacuum gasified oil (VGO) blend feedstock sample of Example 3 was evaluated. The all-liquid product of the AR1 / VGO feedstock blend (45 wt% AR1, 55 wt% VGO) was distilled into eight fractions, with the heaviest fraction having a fractionating point of 911℉. Distillation modeling showed that the all-liquid product from a 40,000 BPOD hydrocracker feedstock could be distilled into the following products: 6,150 BPOD bright and slip base oil products (29.9 cSt at 100°C, VI 117, 1005℉+), corresponding to 11% of the product; 8,310 BPOD of waxy heavy 600 neutral base oil products (11.69 cSt at 100°C, VI 112,898-1005℉), corresponding to 15% of the product; 13,010 BPOD wax-containing 220 neutral base oil products (6.0 cSt at 100°C, VI 108.754-898℉), corresponding to 24% of the product; and 27,470 BPOD total waxy base oil products, 754℉+ oil, corresponding to 50% of liquid products.

[0091] In the aforementioned examples, using atmospheric residual oil as feedstock or feedstock blends has shown advantages in allowing the production of extra-heavy base oils, including bright and slippery oils, via a fully hydrotreated route. Using AR feedstock components can result in higher yields and product quality, and allows for the processing of feedstock blends with heavier components and higher endpoints. While variations in fractionation targets and conditions can lead to additional or different properties in the base oil product, using atmospheric residual oil feedstock enables the production of extra-heavy base oils, including bright and slippery oils, that are typically not obtainable by processing typical or standard base oil feedstocks alone without solvent deasphalting.

[0092] The above description of one or more embodiments of the present invention is primarily for illustrative purposes. It should be understood that variations that still encompass the essence of the invention may be used. The following technical solutions should be referenced when determining the scope of the invention.

[0093] For the purposes of U.S. patent practice and where permitted by other patent offices, all patents and publications referenced in the preceding description of this invention are incorporated herein by reference, provided that any information contained therein is related to and / or supplements the preceding disclosure.

Claims

1. A process for manufacturing a bright lubricating oil base oil, the process comprising contacting a base oil feed stream containing atmospheric residual oil feedstock and, where appropriate, base oil feedstock under hydrocracking conditions with a hydrocracking catalyst to form a hydrocracking product; separating the hydrocracking product into a gaseous fraction and a liquid fraction; contacting the liquid fraction with a dewaxing catalyst under hydroisomerization conditions to produce a dewaxing product; and, where appropriate, contacting the dewaxing product with a hydrorefining catalyst under hydrorefining conditions to produce a hydrorefined dewaxing product; wherein the atmospheric residual oil feedstock has an API specific gravity greater than about 25° API, a nickel and vanadium content less than about 2 ppm, an MCR of less than about 1% by weight, an asphaltene content of less than about 500 ppm, and a viscosity of less than 10 cSt at 100°C, and wherein the process produces a bright lubricating oil base oil product with a viscosity of at least about 22 cSt at 100°C.

2. The process described in claim 1, wherein the base oil feed stream includes base oil raw materials.

3. For the process described in Request 1 or 2, the atmospheric residual oil feedstock shall meet one or more of the following conditions: API specific gravity in the range of 25-60; VI in the range of 50-200; viscosity at 100°C in the range of 3-30 cSt; viscosity at 70°C in the range of 5-25 cSt; hot C7 asphaltene content in the range of 0.01-0.3% by weight; wax content in the range of 5-40% by weight; nitrogen content less than 2500 ppm; sulfur content less than 8000 ppm; and 1050+℉ content in the range of 5-50% by weight.

4. The process of claim 1 or 2, wherein the atmospheric residual oil feedstock has the following characteristics: the hot C7 asphaltene content is less than about 0.3% by weight; and the nitrogen content is less than 2500 ppm.

5. The process of claim 1 or 2, wherein the atmospheric residual oil feedstock has the following characteristics: hot C7 asphaltene content is less than about 0.3% by weight; nitrogen content is less than 2500 ppm; and metal content is less than about 5 ppm of nickel, or less than about 3 ppm of vanadium, or less than about 4 ppm of iron, or a combination thereof.

6. For the process described in claim 1 or 2, wherein the atmospheric residual oil feedstock meets the following conditions: viscosity at 100°C in the range of 3-10 cSt; hot C7 asphaltene content in the range of less than about 0.1% by weight; MCRT less than 2% by weight; nitrogen content less than 800 ppm; sulfur content less than 3000 ppm; nickel content less than 5 ppm; vanadium content less than 3 ppm; and iron content less than 4 ppm.

7. For the process described in Request 1 or 2, the base oil feedstock shall meet one or more of the following conditions: API specific gravity in the range of 15-40; VI in the range of 30-90; viscosity at 100°C in the range of 3-30 cSt; viscosity at 70°C in the range of 5-50 cSt; hot C7 asphaltene content in the range of 0.01-0.3% by weight; wax content in the range of 5-90% by weight; nitrogen content less than 2500 ppm; sulfur content less than 40000 ppm; 1050+℉ content less than 10% by weight.

8. The process described in claim 1 or 2, wherein the base oil feedstock has the following characteristics: nitrogen content less than 2500 ppm; sulfur content less than 40000 ppm; 1050+℉ content less than 10% by weight; or a combination thereof.

9. The process described in claim 1 or 2, wherein the base oil feed stream comprises 5-95% by weight of atmospheric residual oil feedstock and 95-5% by weight of base oil feedstock.

10. The process described in claim 1 or 2, wherein the base oil feed stream does not contain any added crude oil feedstock, vacuum residual oil feedstock, deasphalted oil, or only atmospheric residual oil feedstock, or only atmospheric residual oil feedstock and base oil feedstock.

11. The process of claim 1 or 2, wherein the process does not include recycling the liquid feedstock as part of the base oil feed stream or as either or both of the atmospheric residual oil feedstock and the base oil feedstock.

12. In the process described in request item 1 or 2, the atmospheric residual oil feedstock is different from the base oil feedstock.

13. The process of claim 12, wherein the atmospheric residual oil feedstock differs from the base oil feedstock in terms of nitrogen content, sulfur content, 1050+℉ content, or a combination thereof.

14. The process described in claim 1 or 2, wherein the base oil feedstock comprises vacuum-generated oil or is vacuum-generated oil.

15. The process of claim 14, wherein the vacuum gasification oil is a heavy vacuum gasification oil obtained by fractionation of the vacuum gasification oil into light and heavy fractions, wherein the fractionation point temperature range of the heavy fraction is approximately 950-1050℉.

16. The process described in claim 1 or 2, wherein the dewaxing product and / or the hydrorefined dewaxing product are obtained as light base oil products and heavy base oil products.

17. The process of claim 16, wherein the nominal viscosity of the light base oil product is in the range of 3-9 cSt at 100°C, and / or the nominal viscosity of the heavy base oil product is in the range of 13-24 cSt at 100°C.

18. The process of claim 16, wherein, compared with the same process in which the base oil feed stream does not include the atmospheric residual oil feedstock, the yield of the heavy base oil product relative to the light base oil product is increased by at least about 0.5 L vol.%.

19. The process described in claim 16, wherein the total waxy base oil yield is increased by at least about 0.5 L vol. compared to the same process in which the base oil feed stream does not include the atmospheric residual oil feedstock.

20. The process of claim 1 or 2, wherein the dewaxed product is further separated into at least one lighter product or at least one heavier product or a combination thereof, wherein the nominal viscosity of the at least one lighter product is 5.5 to 7.5 cSt at 100°C, and the nominal viscosity of the at least one heavier product is 13 cSt or higher at 100°C.

21. The process of claim 1 or 2, wherein the base oil feedstock comprises tight oil or a fraction thereof, and / or the atmospheric residual oil feedstock is derived from tight oil or a fraction thereof.

22. A method for modifying a base oil processing step for producing a bright, slippery oil base oil with a viscosity of at least about 22 cSt at 100°C, wherein the base oil processing step includes subjecting a base oil feed stream to a hydrocracking step and a dewaxing step to form a dewaxed product comprising light and heavy products; the method includes subjecting the base oil feed stream comprising the atmospheric residual oil feedstock to the hydrocracking step and the dewaxing step of the base oil processing step; wherein the modified base oil processing step is the process described in any one of claims 1 to 21.

23. A process for producing a bright, slippery oil base oil with a viscosity of at least about 22 cSt at 100°C from a base oil feed stream or its fractions, the process comprising providing a base oil feed stream containing atmospheric residual oil feedstock and, where appropriate, a base oil feedstock; separating the base oil feed stream or its fractions into vacuum gasification oil fractions with a front-end fractionation point of about 700°F or higher and a rear-end fractionation point of about 900°F or lower to form a medium vacuum gasification oil (MVGO) fraction and a heavy vacuum gasification oil (HHVGO) fraction; and using the HHVGO fraction as the atmospheric residual oil feedstock in any of the processes claimed in claims 1 to 21.

24. The process of claim 23, further comprising: contacting the MVGO fraction with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracking product; separating the hydrocracking product into a gaseous fraction and a liquid fraction; contacting the liquid fraction with a dewaxing catalyst under hydroisomerization conditions to produce a dewaxing product; and, where appropriate, contacting the dewaxing product with a hydrorefining catalyst under hydrorefining conditions to produce a hydrorefined dewaxing product; wherein, The viscosity index of the dewaxed product and / or the hydrotreated dewaxed product is 120 or higher after dewaxing.

25. The process described in claim 23 or 24, wherein the viscosity index of the dewaxed product and / or the hydrorefined dewaxed product is 130 or higher after dewaxing.

26. The process described in claim 23 or 24, wherein the dewaxing product and / or the hydrorefining dewaxing product comprises Group III or Group III+ base oil products.

27. The process of claim 23 or 24, wherein the hydrocracking product has a viscosity index of at least about 135.

28. A process for producing a bright, slippery oil base oil with a viscosity of at least about 22 cSt at 100°C from a base oil feed stream or its fractions, the process comprising: providing a base oil feed stream containing atmospheric residual oil feedstock and, where appropriate, a base oil feedstock; separating the base oil feed stream or its fractions into vacuum gasification oil fractions with a front-end fractionating point of about 700°F or higher and a rear-end fractionating point of about 900°F or lower, to form a medium vacuum gasification oil (MVGO) fraction and a heavy vacuum gasification oil (HHVGO) fraction; contacting the base oil feed stream containing the HHVGO fraction and, where appropriate, the base oil feedstock, with a hydrocracking catalyst under hydrocracking conditions to form hydrocracking products; and separating the hydrocracking products into gaseous and liquid fractions. The liquid fraction is contacted with a dewaxing catalyst under hydroisomerization conditions to produce a dewaxed product; and, if appropriate, the dewaxed product is contacted with a hydrorefining catalyst under hydrorefining conditions to produce a hydrorefined dewaxed product; wherein the atmospheric residual oil feedstock has an API specific gravity greater than about 25° API, a nickel and vanadium content less than about 2 ppm, an MCR of less than about 1% by weight, and an asphaltene content of less than about 500 ppm, and wherein the process produces a bright lubricating oil base oil product with a viscosity of at least about 22 cSt at 100°C.

29. The process of claim 28, further comprising: contacting the MVGO fraction with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracking product; separating the hydrocracking product into a gaseous fraction and a liquid fraction; contacting the liquid fraction with a dewaxing catalyst under hydroisomerization conditions to produce a dewaxing product; and, where appropriate, contacting the dewaxing product with a hydrorefining catalyst under hydrorefining conditions to produce a hydrorefined dewaxing product; wherein, The viscosity index of the dewaxed product and / or the hydrotreated dewaxed product is 120 or higher after dewaxing.

30. The process described in claim 28 or 29, wherein the viscosity index of the dewaxed product and / or the hydrorefined dewaxed product is 130 or higher after dewaxing; or wherein the dewaxed product and / or the hydrorefined dewaxed product contains Group III or Group III+ base oil products; or wherein the hydrocracking product has a viscosity index of at least about 135.

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