Process and system for converting crude oil to chemicals

Abstract

The present invention relates to systems and methods for processing crude oil to produce more chemical feedstocks, such as light olefins, lubricant oils, and fuels. One such system includes processing different streams from a crude oil distillation complex by at least two diesel hydroprocessors operating at two different pressures.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit and priority of U.S. Provisional Application No. 63 / 589,769, filed October 12, 2023, which is incorporated herein by reference in its entirety. Technical Field

[0003] This disclosure generally relates to systems and methods for processing crude oil to produce more chemical feedstocks, such as light olefins, lubricants, and fuels. Background Technology

[0004] Conventional refineries are equipped with process units focused on maximizing transportation fuel production. The yield of chemical feedstocks depends on the complexity of the refinery. Crude oil to chemicals (COTC) technology involves refinery complexes configured to shift production from transportation fuels to producing more than 40% chemicals per unit weight of oil. To facilitate increased demand for chemical feedstocks and decreased demand for transportation fuels, the percentage of chemicals per unit weight of oil must be significantly increased. Summary of the Invention

[0005] To address these industry needs and other technological deficiencies, the applicant has developed systems and methods for processing crude oil into chemical feedstocks. This document provides methods for producing light olefins, lubricating oils, and fuels from crude oil feedstocks. In some examples, the method includes the step of fractionating the crude oil feedstock to produce a first naphtha subtractive product, a kerosene fraction, a light atmospheric gas oil fraction, a heavy atmospheric gas oil fraction, a light vacuum gas oil fraction, a medium vacuum gas oil fraction, a heavy vacuum gas oil fraction, and a vacuum residue fraction. The method includes hydrotreating a first portion of the light atmospheric gas oil fraction and the kerosene fraction at a pressure less than about 40 bar gauge pressure to produce a first diesel product and a second naphtha subtractive product; and hydrotreating a second portion of the light atmospheric gas oil fraction and the light vacuum gas oil fraction at a pressure greater than about 60 bar gauge pressure to produce a first tail gas, a second diesel product, and a third naphtha subtractive product. In some examples, the first fraction of the light atmospheric gas oil fraction and the kerosene fraction are subjected to hydrotreating at pressures ranging from about 25 bar gauge pressure to about 40 bar gauge pressure. In some examples, the second fraction of the light atmospheric gas oil fraction and the light vacuum gas oil fraction are subjected to hydrotreating at pressures ranging from about 60 bar gauge pressure to about 80 bar gauge pressure.

[0006] The method further includes hydrocracking heavy atmospheric gas oil, medium vacuum gas oil fractions, and heavy vacuum gas oil fractions in the presence of a hydrocracking catalyst to produce second tail gas, fourth naphtha subtractive product, third diesel product, base oil product, and unconverted oil product. The second tail gas may be cracked in the presence of steam. The method also includes catalytic hydrocracking of unconverted oil product (containing unconverted oil with low paraffin content) and vacuum residue fraction to produce third tail gas, fifth naphtha subtractive product, fourth diesel product, middle distillate product, and heavy distillate product. The method further includes cracking first naphtha subtractive product, second naphtha subtractive product, third naphtha subtractive product, fourth naphtha subtractive product, and fifth naphtha subtractive product in the presence of steam to produce light olefins; and processing first diesel product, second diesel product, and third diesel product to produce fuel. The method also includes supplying base oil product and heavy distillate product to a lubricant production area to produce lubricants. The lubricant production area may include selective hydrotreating, MTBE process, and full hydrotreating. In some examples, heavy distillate products and / or deasphalted oil and asphalt and / or low-sulfur fuel oil are fed to a gas oil hydrocracker. In some examples, the second tail gas may be cracked in the presence of steam. In some examples, base oil products containing unconverted oil with high paraffin content are cracked in the lubricant production area or in the presence of steam. In some examples, cracked oil from a steam cracker and / or heavy aromatics streams from an aromatics extraction unit are hydrocracking together with unconverted oil products. In some examples, medium distillate products are hydrotreated together with a second fraction of light atmospheric gas oil and light vacuum gas oil at a pressure greater than about 60 bar gauge pressure. In some examples, heavy distillate products and / or deasphalted oil and asphalt and / or low-sulfur fuel oil are hydrocracking in a gas oil hydrocracker. In some examples, the second naphtha subtractive product is a crude naphtha fraction that undergoes fractionation downstream in a CDU stabilization unit to separate liquefied petroleum gas and naphtha.

[0007] In some examples, the crude oil feedstock undergoes fractionation in a crude oil distillation complex, including an atmospheric distillation unit to process the crude oil feedstock to produce first naphtha minus products, kerosene fraction, light atmospheric gas oil fraction, heavy atmospheric gas oil fraction, and atmospheric residue, and a vacuum distillation unit to process the atmospheric residue to produce light vacuum gas oil fraction, medium vacuum gas oil fraction, and vacuum residue fraction. In some examples, a portion of the vacuum residue fraction undergoes a solvent deasphalting process to produce deasphalted oil supplied to a gas oil hydrocracker. In some examples, cracked oil from a steam cracker and / or heavy oil fraction from a gas oil hydrocracker are supplied as additional feed to the residue hydrocracker. In some examples, catalytic hydrocracking of unconverted oil products and vacuum residue fraction produces asphalt and marine residue fuel oil. In some examples, the marine residue fuel oil has a sulfur content of up to 0.5%.

[0008] Some implementations include systems that produce light olefins, lubricants, and fuels from crude oil feedstock. These systems include a crude oil distillation complex, a first diesel hydrocracking unit, a second diesel hydrocracking unit, a steam cracking zone, a fuel processing zone, a gas oil hydrocracker, a residue hydrocracker, and a lubricant production zone.

[0009] In some examples, the crude oil distillation unit is configured to fractionate the crude oil feed to produce first naphtha minus products, kerosene fraction, light atmospheric gas oil fraction, heavy atmospheric gas oil fraction, light vacuum gas oil fraction, medium vacuum gas oil fraction, heavy vacuum gas oil fraction, and vacuum residue fraction.

[0010] The crude oil distillation unit is connected to and in fluid communication with at least two diesel hydrotreating units. A first diesel hydrotreating unit is configured to receive a first fraction of a light atmospheric gas oil fraction and a kerosene fraction, and operates at a pressure less than about 40 bar gauge pressure to produce a first diesel product and a second naphtha subtractive product. The first diesel hydrotreating unit can operate at a pressure ranging from about 25 bar gauge pressure to about 40 bar gauge pressure. In some examples, the second naphtha subtractive product is a crude naphtha fraction that undergoes fractionation downstream in a CDU stabilization unit to separate liquefied petroleum gas and naphtha. A second diesel hydrotreating unit is configured to receive a second fraction of a light atmospheric gas oil fraction and a light vacuum gas oil fraction, and operates at a pressure greater than about 60 bar gauge pressure to produce a first tail gas, a second diesel product, and a third naphtha subtractive product. In some examples, the second diesel hydrotreating unit operates at a pressure ranging from about 60 bar gauge pressure to about 80 bar gauge pressure.

[0011] The crude oil distillation unit is connected to and in fluid communication with the gas oil hydrocracker. The gas oil hydrocracker is configured to receive heavy atmospheric gas oil, medium vacuum gas oil fraction, and heavy vacuum gas oil fraction from the crude oil distillation unit, and to produce a first hydrocracking product, base oil product, and unconverted oil product in the presence of a hydrocracking catalyst. The first hydrocracking product may include a second tail gas, a fourth naphtha subtractive product, and / or a third diesel product, all of which can be fed to a steam cracking zone. In some examples, the second tail gas and the fourth naphtha subtractive product are fed to the steam cracking zone to produce light olefins. The base oil product from the gas oil hydrocracker, containing unconverted oil with a high paraffin content, is fed to a lubricant production zone or a steam cracking zone to produce light olefins. The lubricant production zone may include selective hydrotreating, MTBE process, and full hydrotreating.

[0012] The gas oil hydrocracker is connected to and in fluid communication with the residue hydrocracker and lubricating oil production area. The residue hydrocracker is configured to receive unconverted oil products from the gas oil hydrocracker and vacuum residue fraction from the crude oil fractionation unit, and to produce second hydrocracking products, middle distillate products, and heavy distillate products. The second hydrocracking products include one or more of a third tail gas, a fifth naphtha subtractive product, and a fourth diesel product. In some examples, the third tail gas, the fifth naphtha subtractive product, and the fourth diesel product are all supplied to a steam cracking zone to produce light olefins. In some examples, the third tail gas and the fifth naphtha subtractive product are supplied to a steam cracking zone to produce light olefins, and the fourth diesel product is supplied to a fuel processing zone to produce fuel. This fuel is one or more of gasoline, jet fuel, and diesel fuel. The middle distillate products from the residue hydrocracker are recycled to the second diesel hydrotreating unit. The heavy distillate from the residue hydrocracker is recycled back to the gas oil hydrocracker. In some examples, a first portion of the heavy distillate from the residue hydrocracker is recycled back to the gas oil hydrocracker, and a second portion of the heavy distillate from the residue hydrocracker is supplied to the lubricant production area to produce lubricant.

[0013] In some examples, pyrolysis oil from the steam cracker and / or heavy aromatics streams from the aromatics extraction unit are supplied to the residue hydrocracker along with unconverted oil products. In some examples, a portion of the vacuum residue fraction undergoes a solvent deasphalting process to produce deasphalted oil supplied to the gas oil hydrocracker. In some examples, cracked oil from the steam cracker and / or heavy oil fractions from the gas oil hydrocracker are supplied as additional feed to the residue hydrocracker. In some examples, catalytic hydrocracking of unconverted oil products and vacuum residue fractions produces asphalt and marine residue fuel oil. In some examples, the marine residue fuel oil has a sulfur content of up to 0.5% by weight.

[0014] This document also discusses in detail other aspects and advantages of these exemplary embodiments and other embodiments. Furthermore, it should be understood that the foregoing information and the following detailed description are merely illustrative examples of various aspects and embodiments, and are intended to provide an overview or framework for understanding the nature and characteristics of the claimed aspects and embodiments. Moreover, it should be understood that the features of the various embodiments described herein are not mutually exclusive and can exist in various combinations and arrangements. Attached Figure Description

[0015] The accompanying drawings are included to provide a further understanding of embodiments of this disclosure, are incorporated into and form part of this specification, illustrate embodiments of this disclosure, and, together with the detailed description, serve to explain the principles of the embodiments discussed herein. No attempt is made to show the structural details of this disclosure in a manner more detailed than is necessary for a basic understanding of the embodiments discussed herein and their various implementable forms.

[0016] Figure 1 This is a schematic illustration of a system for processing crude oil to produce more chemical feedstocks such as light olefins, lubricating oils and fuels, according to embodiments of this disclosure. Detailed Implementation

[0017] This disclosure describes various embodiments related to processes, methods, and systems for processing crude oil to produce further chemical feedstocks such as light olefins, lubricants, and fuels. Further embodiments may be described and disclosed.

[0018] The following description provides numerous details to offer a thorough understanding of the various embodiments. In other instances, well-known processes, apparatus, and systems have not been described in particular detail to avoid unnecessarily obscuring the embodiments. Furthermore, the descriptions of the various embodiments may omit certain features or details to avoid obscuring them.

[0019] The specification may use the phrases "in some embodiments," "in various embodiments," "in one embodiment," or "in certain embodiments," each of which may refer to one or more of the same or different embodiments. Furthermore, the terms "comprising," "including," "having," etc., used in relation to embodiments of the invention are synonymous.

[0020] The term "approximately" refers to a range of values ​​that will be reasonably considered by those skilled in the art to be reasonably similar to the specified value. In embodiments, "approximately" refers to a value within a standard deviation using measurements generally acceptable in the art. In a non-limiting embodiment, when the term "approximately" is used with a specific value, "approximately" refers to a range extending to ±10% of the specified value, alternatively ±5% of the specified value, or alternatively ±1% of the specified value, or alternatively ±0.5% of the specified value. In embodiments, "approximately" refers to the specified value.

[0021] When used in the claims and / or specification, the terms “reduction,” “reduced,” or any variation thereof include any measurable reduction or complete removal to achieve the desired result.

[0022] When used in conjunction with any of the terms “comprising,” “including,” “containing,” or “having” in the claims or description, the word “an” or “a” can mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more.” The terms “weight%,” “volume%,” or “molar%” refer to the weight, volume, or molar percentage of a component, based on the total weight, volume, or moles of the material comprising that component. In a non-limiting example, 10 grams of a component in 100 grams of material is 10% by weight of such a component. The terms “enriched” or “rich” and their variations refer to a compound or class of compounds in a stream of material in an amount of at least, typically about 20% by weight, preferably about 25% by weight.

[0023] Hydrocarbon molecules can be abbreviated as C1, C2, C3…C n The superscript "n" indicates the number of carbon atoms in one or more hydrocarbon molecules. Additionally, superscripts "+" or "-" or the terms "plus" and "minus" can be used with abbreviated hydrocarbon symbols, such as Cn. 3+ Or C 3- This includes one or more hydrocarbons abbreviated as C3+. For example, the term "C3+" means one or more hydrocarbon molecules with three carbon atoms and / or more. The term "naphtha minus product" refers to a hydrocarbon oil fraction in which at least 80% by weight, suitably at least 85% by weight, of hydrocarbons have a boiling point lower than that of naphtha (about 165°C).

[0024] As used herein, the term "zone" can refer to a region comprising one or more units and / or one or more subzones. A unit may include one or more reactors or reactor vessels, separators, strippers, extraction columns, fractionation columns, heaters, exchangers, piping, pumps, compressors, and controllers. Furthermore, a unit such as a reactor, dryer, or vessel may also comprise one or more zones or subzones containing various equipment.

[0025] COTC technology allows crude oil to be directly converted into high-value chemical products, rather than as a traditional transportation fuel. In some examples, it enables the production of chemicals to exceed 70% to 80% of the feedstock produced in barrels, compared to approximately 10% in unintegrated refinery complexes. The applicant has developed systems and methods involving innovative configurations of process units.

[0026] The systems and methods disclosed herein pertain to configurations involving at least two diesel hydrotreating units. For example, one diesel hydrotreating unit is used for desulfurization, and the second diesel hydrotreating unit is used for cloud point correction. In some examples, the diesel hydrotreating units operate at approximately 30 bar gauge pressure and are supplied with a portion of light atmospheric gas oil from a crude oil fractionation complex and kerosene. The first diesel hydrotreating unit has one reactor for desulfurization. The second diesel hydrotreating unit operates at a pressure greater than 60 bar gauge pressure and has two reactors—one for desulfurization and the other for cloud point correction. The feed to the second hydrotreating unit is a second portion of light atmospheric gas oil, light vacuum gas oil, and middle distillate from a residue hydrocracking unit. Heavy atmospheric gas oil is not supplied to the second diesel hydrotreating unit. In some examples, the lubricant production area has selective hydrotreating and a full hydrotreating unit added before the MTBE. Some advantages of having two diesel hydrotreating units include the effect on turndown, a reduction in the number of reactors from four to three, and operating one of the reactors at approximately half the pressure. Changing the feed composition of the second diesel hydrotreating unit to exclude heavy atmospheric gas oil and / or include medium distillates from the residue hydrocracker reduces the load on the second diesel hydrotreating unit for cloud point adjustment and increases the hydraulic load.

[0027] This article provides a method for producing light olefins, lubricating oils, and fuels from crude oil feedstock. In some examples, the method includes the step of fractionating the crude oil feedstock to produce first naphtha minus products, kerosene fraction, light atmospheric gas oil fraction, heavy atmospheric gas oil fraction, light vacuum gas oil fraction, medium vacuum gas oil fraction, heavy vacuum gas oil fraction, and vacuum residue fraction.

[0028] Crude oil feed fractionation typically occurs in a crude oil distillation complex. This complex can be a single unit or two units. A two-unit structure comprises an atmospheric distillation unit and a vacuum distillation unit. Here, the crude oil feed is fractionated into first naphtha minus products, kerosene fraction, light atmospheric gas oil fraction, heavy atmospheric gas oil fraction, and atmospheric residue. The atmospheric residue is further fractionated in the vacuum distillation unit to produce light vacuum gas oil fraction, medium vacuum gas oil fraction, heavy vacuum gas oil fraction, and vacuum residue fraction.

[0029] Naphtha fractions, minus products, contain hydrocarbons with boiling points less than 195°C. Kerosene fractions contain hydrocarbons with boiling points ranging from about 195 to 270°C. Light atmospheric gas oil fractions contain hydrocarbons with boiling points ranging from about 270 to 321°C. Heavy atmospheric gas oil fractions contain hydrocarbons with boiling points ranging from about 321 to 425°C. Heavy vacuum gas oil may include hydrocarbons with boiling points ranging from about 490°C to 590°C or about 340°C to 560°C at about 101.3 kPa. Medium vacuum gas oil may include hydrocarbons with boiling points ranging from about 400°C to about 490°C at about 101.3 kPa. Light vacuum gas oil may include hydrocarbons with boiling points ranging from about 370°C to 400°C at about 101.3 kPa. Vacuum residue fractions contain hydrocarbons with boiling points greater than 565°C.

[0030] In some examples, the method includes hydrotreating a first fraction of a light atmospheric gas oil fraction and a kerosene fraction at a pressure less than about 40 bar gauge pressure in the presence of a hydrotreating catalyst and hydrogen to produce a first diesel product and a second naphtha subtractive product; and hydrotreating a second fraction of a light atmospheric gas oil fraction and a light vacuum gas oil fraction at a pressure greater than about 60 bar gauge pressure in the presence of a hydrotreating catalyst and hydrogen to produce a second diesel product and a third naphtha subtractive product. This step may result in the generation of a first tail gas. In some examples, the hydrotreating is primarily diesel hydrotreating, which reduces sulfur and nitrogen by selectively reacting them with hydrogen in a reactor at specific pressures to produce diesel products. In some examples, the first fraction of the light atmospheric gas oil fraction and the kerosene fraction undergo hydrotreating at pressures ranging from about 25 bar gauge pressure to about 45 bar gauge pressure. In some examples, the first hydrotreating step is carried out at a pressure range of about 25 bar to about 40 bar, or about 30 bar to about 40 bar, or about 28 bar to about 38 bar, or about 35 bar to about 40 bar, or about 35 bar to about 45 bar. In some examples, the second fraction of the light atmospheric gas oil fraction and the light vacuum gas oil fraction are hydrotreated at a pressure range of about 60 bar to about 80 bar. In some examples, the second hydrotreating step is carried out at a pressure range of about 60 bar to about 78 bar, or about 60 bar to about 75 bar, or about 60 bar to about 70 bar, or about 65 bar to about 75 bar, or about 68 bar to about 78 bar.

[0031] The method also includes hydrocracking heavy atmospheric gas oil, medium vacuum gas oil fraction, and heavy vacuum gas oil fraction in the presence of a hydrocracking catalyst to produce a first hydrocracking product, base oil product, and unconverted oil product. This hydrocracking step is typically carried out in a gas oil hydrocracker. A single-stage gas oil hydrocracker can operate at temperatures ranging from 340°C to approximately 430°C and pressures ranging from 1200 to 2000 psig (82 bar to 138 bar). The first hydrocracking product may contain a fourth naphtha subtractive product and / or a third diesel product, all of which can be supplied to a steam cracking zone for conversion to olefins. This step may also result in the production of a second tail gas, which can be cracked in the presence of steam. In some examples, the gas oil hydrocracking feed containing the heavy atmospheric gas oil, medium vacuum gas oil fraction, and heavy vacuum gas oil fraction is treated to remove sulfur and / or nitrogen before undergoing catalytic hydrocracking.

[0032] In some examples, the hydrocracking step, relative to the feedstocks of heavy atmospheric gas oil, medium vacuum gas oil, and heavy vacuum gas oil, produces approximately 70 wt% to approximately 99 wt% of hydrocracking products (as second tail gas), fourth naphtha subtractive product, third diesel product, and base oil product, with the balance being 1 wt% to 30 wt% of unconverted oil products. In some examples, the second tail gas, fourth naphtha subtractive product, third diesel product, and base oil product constitute approximately 75 wt%, or 80 wt%, or 85 wt%, or 90 wt%, or 95 wt% of the hydrocracking products. In some examples, the hydrocracking products are passed to a fractionating zone to recover the second tail gas, fourth naphtha subtractive product, third diesel product, and base oil product, and to separate the unconverted oil products. In some examples, the second hydrocracking products, fourth naphtha subtractive product, and third diesel product containing the second tail gas are supplied to a steam cracking zone.

[0033] In some examples, the second tail gas containing H2, H2S, NH3, and light hydrocarbons (C1-C4) can be recovered and further processed in the fuel processing zone. LPG can be recovered and directed to the steam cracking zone, fuel processing zone, and / or saturated gas unit. The fourth naphtha subtractive product and the third diesel product can be recovered from a fractionation zone that separates these components at a suitable cut-off point, for example, within a temperature range corresponding to the upper limit of the diesel product range. In some embodiments, a suitable cut-off point can be in the range of 350 to 450°C, 350 to 400°C, 360 to 400°C, 370 to 420°C, 380 to 430°C, or 360 to 380°C.

[0034] The method also includes catalytic hydrocracking of unconverted oil products (containing unconverted oil with low paraffin content) and vacuum residue fractions to produce second hydrocracking products, middle distillate products, and heavy distillate products. The second hydrocracking products contain third tail gas, fifth naphtha subtraction products, and fourth diesel products, all of which can be supplied to the steam cracking zone for conversion into olefins.

[0035] The hydrotreating of unconverted oil products and residual streams from vacuum residue depends on the type and level of contaminants (e.g., asphaltenes, metals, and sulfur) and the carbon residue content. Residue upgrading technologies can be implemented using fixed-bed hydrocrackers, fluidized-bed reactors, slurry-liquid reactors, or continuous catalyst displacement reactors. In some examples, these reactors operate at temperatures above 450°C and pressures up to 270 bar gauge pressure. For example, hydrocracking processes can be operated to achieve reaction conditions with temperature variations of 300–480°C and pressure variations of 35–260 bar gauge pressure.

[0036] The method further includes cracking the first naphtha subtractive product, the second naphtha subtractive product, the third naphtha subtractive product, the first hydrocracking product, and the second hydrocracking product in the presence of steam to produce light olefins. The light olefins may be one or more of C2-C4 olefins, and optionally one or more of benzene, toluene, xylene, naphtha, fuel gas, butadiene, C5+ hydrocarbons, fuel oil, or combinations thereof. One or more of the C2-C4 olefins may be recovered in an olefin recovery zone operated to produce compliant light olefin (ethylene and propylene) products from the mixed product stream. The method also includes treating the first diesel product, the second diesel product, and the third diesel product to produce fuel.

[0037] The method also includes processing base oil products and heavy distillate products to produce lubricating oils. This processing can be carried out in a lubricating oil production area, which may include selective hydrotreating, an MTBE process for producing methyl tert-butyl ether (MTBE), and full hydrotreating to convert any olefin into saturated hydrocarbons.

[0038] In some examples, heavy distillate products and / or deasphalted oil and bitumen and / or low-sulfur fuel oil are supplied to a gas oil hydrocracker. In some examples, the second tail gas may be cracked in the presence of steam. In some examples, base oil products containing unconverted oil with high paraffin content are cracked in the lubricating oil production zone or in the presence of steam. In some examples, cracked oil from a steam cracker and / or heavy aromatics streams from an aromatics extraction unit are hydrocracking together with unconverted oil products. In some examples, medium distillate products are hydrotreated together with a second fraction of light atmospheric gas oil and a light vacuum gas oil fraction at pressures greater than about 60 bar gauge pressure. In some examples, heavy distillate products and / or deasphalted oil and bitumen and / or low-sulfur fuel oil are hydrocracking in a gas oil hydrocracker. In some examples, the second naphtha subtractive product is a crude naphtha fraction that undergoes fractionation downstream in a CDU stabilization unit to separate liquefied petroleum gas and naphtha.

[0039] In some examples, the crude oil feedstock undergoes fractionation in a crude oil distillation complex comprising (a) an atmospheric distillation unit to process the crude oil feedstock to produce a first naphtha subtractive product, kerosene fraction, light atmospheric gas oil fraction, heavy atmospheric gas oil fraction, and atmospheric residue, and (b) a vacuum distillation unit to process the atmospheric residue to produce a light vacuum gas oil fraction, a medium vacuum gas oil fraction, and a vacuum residue fraction. In some examples, a portion of the vacuum residue fraction undergoes a solvent deasphalting process to produce deasphalted oil supplied to a gas oil hydrocracker. In some examples, cracked oil from a steam cracker and / or heavy oil fraction from a gas oil hydrocracker are supplied as additional feed to a residue hydrocracker. In some examples, a step of catalytic hydrocracking unconverted oil products and vacuum residue fraction produces asphalt and marine residue fuel oil.

[0040] This document provides a system for producing light olefins, lubricants, and fuels from crude oil feedstock. Although this disclosure primarily describes crude oil as the feedstock, it may also include crude naphtha, LPG, and tail gas streams from diesel hydrotreating areas and other hydrotreating areas. Components not shown but that may be included in a crude oil distillation complex are a feed / product and pump cycle heat exchanger, a crude oil feed heater, a crude oil tower, a product stripper, a cooling system, a tower top hot / cold tank system (including a re-contaminator and a tail gas compressor), and a water washing unit for the tower top condensate system.

[0041] In some examples, systems for producing light olefins, lubricants, and fuels from crude oil feedstocks include a crude oil distillation complex, two diesel hydrocracking processors operating under two different pressure conditions, a steam cracking zone, a diesel processing zone, a gas oil hydrocracking zone, a residue hydrocracking zone, and a lubricant processing zone.

[0042] In some examples, the crude oil distillation unit is configured to separate crude oil feedstock into one or more of the following: first naphtha minus products, kerosene fraction, light atmospheric gas oil fraction, heavy atmospheric gas oil fraction, light vacuum gas oil fraction, medium vacuum gas oil fraction, heavy vacuum gas oil fraction, and vacuum residue fraction.

[0043] In some examples, the crude oil distillation unit includes (a) an atmospheric distillation unit to process crude oil feedstock to produce first naphtha minus products, kerosene fraction, light atmospheric gas oil fraction, heavy atmospheric gas oil fraction and atmospheric residue, and (b) a vacuum distillation unit to process atmospheric residue to produce light vacuum gas oil fraction, medium vacuum gas oil fraction and vacuum residue fraction.

[0044] The crude oil distillation unit is connected to and in fluid communication with two diesel hydrotreating processors. The first diesel hydrotreating processor is configured to hydrotreat a first fraction of a light atmospheric gas oil fraction and a kerosene fraction at a pressure less than about 40 bar gauge pressure in the presence of a hydrotreating catalyst and hydrogen to produce a first diesel product and a second naphtha subtractive product. The second diesel hydrotreating processor is configured to hydrotreat a second fraction of a light atmospheric gas oil fraction and a light vacuum gas oil fraction at a pressure greater than about 60 bar gauge pressure in the presence of a hydrotreating catalyst and hydrogen to produce a second diesel product, a third naphtha subtractive product, and optionally a first tail gas. In some examples, the second diesel hydrotreating processor is configured to have dewaxing capabilities. The diesel hydrotreating processors reduce sulfur and nitrogen in a reactor at specific pressures to produce diesel products by selectively reacting these substances with hydrogen to produce diesel products. In some examples, the first diesel hydrotreating processor is configured to hydrotreat a first fraction of the light atmospheric gas oil fraction and the kerosene fraction at a pressure of about 25 bar to about 45 bar. In some examples, the first hydrotreating processor operates at a pressure of about 25 bar to about 40 bar, or about 30 bar to about 40 bar, or about 28 bar to about 38 bar, or about 35 bar to about 40 bar, or about 35 bar to about 45 bar. In some examples, the second hydrotreating processor operates at a pressure of about 60 bar to about 80 bar. In some examples, the second hydrotreating processor operates at a pressure of about 60 bar to about 78 bar, or about 60 bar to about 75 bar, or about 60 bar to about 70 bar, or about 65 bar to about 75 bar, or about 68 bar to about 78 bar.

[0045] Diesel hydrotreating processors can be one or more fixed beds, fluidized beds, slurry beds, moving beds, continuous stirred tanks, or tubular reactors, arranged in series and / or parallel. These diesel hydrotreating processors contain one or more hydrotreating catalysts, including those with hydrotreating functionality. In some examples, the active metal component is one or more of Co, Ni, W, and Mo, deposited on or otherwise incorporated into a support, such as amorphous alumina, amorphous silica alumina, zeolite, or combinations thereof. This combination can consist of different particles containing a single class of active metals or particles containing multiple classes of active metals. In some examples, the diesel hydrotreating processor can comprise a layered bed reactor with one or more catalyst beds. In some examples, a second diesel hydrotreating processor comprises a dewaxing catalyst, such as those used for isomerizing and cracking hydrocarbon feedstocks to improve low-temperature flow properties. In some examples, the second diesel hydrotreating processor can employ a layered catalyst system, wherein a layer of hydrodewaxing catalyst is positioned between beds of hydrotreating catalysts.

[0046] Additional equipment used to feed the reactor and maintain appropriate operating conditions, including exchangers, furnaces, feed pumps, quench pumps, and compressors, is considered part of the diesel hydrotreating unit. Furthermore, equipment used to separate reaction products and provide hydrogen circulation within the diesel hydrotreating unit, including pumps, compressors, high-temperature separation vessels, low-temperature separation vessels, etc., is also considered part of the diesel hydrotreating unit.

[0047] In some implementations, the operating conditions of the diesel hydrotreating processor, optimized based on the type of feedstock and the content of hydrocarbons and contaminants, include reactor inlet temperature, reactor outlet temperature, reaction temperature at the start of operation, reaction temperature at the end of operation, reaction inlet pressure, reaction outlet pressure, hydrogen partial pressure, hydrogen treatment gas feed rate, hydrogen quench gas feed rate, and supplemental hydrogen feed rate.

[0048] In some examples of the system, each diesel hydrotreating unit is connected to and in fluid communication with a steam cracking zone and a fuel processing zone. The steam cracking zone is configured to receive a first naphtha subtractive product, a second naphtha subtractive product, and a third naphtha subtractive product to produce light olefins. The light olefins can be one or more of C2-C4 olefins, and optionally one or more of benzene, toluene, xylene, naphtha, fuel gas, butadiene, C5+ hydrocarbons, and fuel oil, or combinations thereof. In some examples, the fuel processing zone can be a diesel processing unit configured to process the first and second diesel products to produce fuel. First exhaust gas from the second diesel hydrotreating unit can be supplied to the steam cracking zone and / or the fuel processing zone.

[0049] In some examples of the system, the crude oil distillation unit is connected to and in fluid communication with a gas oil hydrocracker. This gas oil hydrocracker is configured to receive (i) medium vacuum gas oil fractions and heavy vacuum gas oil fractions, as well as heavy atmospheric gas oil, from the crude oil distillation unit, and (ii) heavy distillate products (gas oil) and optional deasphalted oil from a downstream residue hydrocracker to produce a first hydrocracking product, a base oil product, and an unconverted oil product in the presence of a hydrocracking catalyst. In some examples, the first hydrocracking product contains a second tail gas, a fourth naphtha subtractive product, and a third diesel product. In some examples, the gas oil hydrocracker is a single-stage gas oil hydrocracker capable of operating in a temperature range of about 340°C to about 430°C and a pressure range of 1200–2000 psig (82 bar–138 bar).

[0050] In some examples, the first hydrocracking product may contain a fourth naphtha subtractive product and / or a third diesel product, which can be processed in a steam cracking zone to convert to olefins. In some examples, the fourth naphtha subtractive product and the third diesel product are separated in a fractionation zone and then supplied to the steam cracking zone and the fuel processing zone, respectively. Processing of gas oil in a gas oil hydrocracker can also result in the generation of a second tail gas, which can be processed in the steam cracking zone. In some examples, the gas oil hydrocracking feedstock containing heavy atmospheric gas oil, medium vacuum gas oil fraction, and heavy vacuum gas oil fraction is treated to remove sulfur and / or nitrogen before undergoing catalytic hydrocracking.

[0051] In some examples, the hydrocracking steps of these fractions, relative to the feedstocks of heavy atmospheric gas oil, medium vacuum gas oil, and heavy vacuum gas oil, produce approximately 70 wt% to approximately 99 wt% of hydrocracking products (as second tail gas), fourth naphtha subtractive products, third diesel products, and base oil products, with the remaining 1 wt% to 30 wt% being unconverted oil products. In some examples, the second tail gas, fourth naphtha subtractive products, third diesel products, and base oil products constitute approximately 75 wt%, or 80 wt%, or 85 wt%, or 90 wt%, or 95 wt% of the hydrocracking products. In some examples, the hydrocracking products are passed to a fractionating zone to recover the second tail gas, fourth naphtha subtractive products, third diesel products, and base oil products, and to separate the unconverted oil products. In some examples, the second hydrocracking product is separated into (i) a second tail gas and a fourth naphtha subtractive product, which are supplied to the steam cracking zone; and (ii) a third diesel product, which are supplied to the fuel processing zone.

[0052] In some examples, the second tail gas containing H2, H2S, NH3, and light hydrocarbons (C1-C4) can be recovered and further processed in the fuel processing zone. LPG can be recovered and directed to the steam cracking zone, fuel processing zone, and / or saturated gas unit. The fourth naphtha subtractive product and the third diesel product can be recovered from a fractionation zone that separates these components at a suitable cut-off point, for example, within a temperature range corresponding to the upper limit of the diesel range products. In some embodiments, a suitable cut-off point can be in the range of 350 to 450°C, 350 to 400°C, 360 to 400°C, 370 to 420°C, 380 to 430°C, or 360 to 380°C.

[0053] In some examples of the system, the gas oil hydrocracker is connected to and in fluid communication with the lubricating oil production zone. This lubricating oil production zone may include selective hydrotreating, an MTBE process for producing methyl tert-butyl ether, and full hydrotreating for the complete removal of unwanted compounds and the near-complete conversion of aromatic and cycloalkanes into desired saturated hydrocarbons. Selective hydrotreating results in significant removal of sulfur compounds and the selective conversion of polycyclic aromatic compounds into partially hydrotreated products containing one aromatic ring, without significantly cracking the oil.

[0054] In some examples of the system, the gas oil hydrocracker is connected to and in fluid communication with the residue hydrocracker and the lubricating oil production zone. The residue hydrocracker is configured to receive unconverted oil products from the gas oil hydrocracker and vacuum residue fractions from the crude oil distillation unit, and to produce second hydrocracking products, middle distillate products supplied to a second diesel hydrotreating unit, and heavy distillate products supplied to the lubricating oil production zone to produce lubricating oil. In some examples, a portion of the heavy distillate products is recycled back to the gas oil hydrocracker. In some examples, the residue hydrocracker is configured to receive pyrolysis oil from a steam cracker and / or heavy aromatics streams from an aromatics extraction unit. In some examples, the residue hydrocracker is configured to produce deasphalted oil and asphalt and / or low-sulfur fuel oil.

[0055] In some examples of the system, the gas oil hydrocracker is connected to and in fluid communication with a solvent deasphalting unit configured to receive a portion of the vacuum residue fraction and produce asphalt and deasphalted oil supplied to the gas oil hydrocracker. In some examples, the residue hydrocracker is also configured to receive cracked oil from a steam cracker unit and a heavy oil fraction from the gas oil hydrocracker. The cracked oil may be derived from a mixed plastic paste. The residue hydrocracker may also be configured to produce asphalt and marine residue fuel oil.

[0056] Some implementations include systems that produce light olefins, lubricants, and fuels from crude oil feedstock. These systems include a crude oil distillation complex, a first diesel hydrocracking unit, a second diesel hydrocracking unit, a steam cracking zone, a fuel processing zone, a gas oil hydrocracker, a residue hydrocracker, and a lubricant production zone.

[0057] In some examples, the crude oil distillation unit is configured to fractionate the crude oil feed to produce first naphtha minus products, kerosene fraction, light atmospheric gas oil fraction, heavy atmospheric gas oil fraction, light vacuum gas oil fraction, medium vacuum gas oil fraction, heavy vacuum gas oil fraction, and vacuum residue fraction.

[0058] The crude oil distillation unit is connected to and in fluid communication with at least two diesel hydrotreating units. A first diesel hydrotreating unit is configured to receive a first fraction of a light atmospheric gas oil fraction and a kerosene fraction, and operates at a pressure less than about 40 bar gauge pressure to produce a first diesel product and a second naphtha subtractive product. The first diesel hydrotreating unit can operate in a pressure range from about 25 bar gauge pressure to about 40 bar gauge pressure. In some examples, the second naphtha subtractive product is a crude naphtha fraction that undergoes fractionation downstream in a CDU stabilization unit to separate liquefied petroleum gas and naphtha. A second diesel hydrotreating unit is configured to receive a second fraction of a light atmospheric gas oil fraction and a light vacuum gas oil fraction, and operates at a pressure greater than about 60 bar gauge pressure to produce a first tail gas, a second diesel product, and a third naphtha subtractive product. In some examples, the second diesel hydrotreating unit operates in a pressure range from about 60 bar gauge pressure to about 80 bar gauge pressure. In some embodiments, each diesel hydrotreating unit may have its own crude oil distillation unit producing different hydrocarbon fractions.

[0059] The crude oil distillation unit is connected to and in fluid communication with a gas oil hydrocracker. The gas oil hydrocracker is configured to receive heavy atmospheric gas oil, medium vacuum gas oil fraction, and heavy vacuum gas oil fraction from the crude oil distillation unit, and to produce first hydrocracking products, base oil products, and unconverted oil products in the presence of a hydrocracking catalyst. The first hydrocracking products may include a second tail gas, a fourth naphtha subtractive product, and / or a third diesel product, all of which may be supplied to a steam cracking zone. In some examples, the second tail gas and the fourth naphtha subtractive product are supplied to the steam cracking zone for the production of light olefins. Base oil products from the gas oil hydrocracker (which contain unconverted oil with high paraffin content) are supplied to a lubricant production zone or to the steam cracking zone for the production of light olefins. The lubricant production zone may include selective hydrotreating, MTBE process, and full hydrotreating.

[0060] The gas oil hydrocracker is connected to and in fluid communication with the residue hydrocracker and lubricating oil production area. The residue hydrocracker is configured to receive unconverted oil products from the gas oil hydrocracker and vacuum residue fraction from the crude oil distillation unit, and to produce second hydrocracking products, middle distillate products, and heavy distillate products. The second hydrocracking products include one or more of a third tail gas, a fifth naphtha subtractive product, and a fourth diesel product. In some examples, the third tail gas, the fifth naphtha subtractive product, and the fourth diesel product are all supplied to a steam cracking zone to produce light olefins. In some examples, the third tail gas and the fifth naphtha subtractive product are supplied to a steam cracking zone to produce light olefins, and the fourth diesel product is supplied to a fuel processing zone to produce fuel. This fuel is one or more of gasoline, jet fuel, and diesel fuel. The middle distillate products from the residue hydrocracker are recycled to the second diesel hydrotreating unit. The heavy distillate from the residue hydrocracker is recycled to the gas oil hydrocracker. In some examples, a first portion of the heavy distillate from the residue hydrocracker is recycled to the gas oil hydrocracker, and a second portion of the heavy distillate from the residue hydrocracker is supplied to the lubricating oil production area to produce lubricating oil.

[0061] In some examples, pyrolysis oil from the steam cracker and / or heavy aromatics streams from the aromatics extraction unit are supplied to the residue hydrocracker along with unconverted oil products. In some examples, a portion of the vacuum residue fraction undergoes a solvent deasphalting process to produce deasphalted oil supplied to the gas oil hydrocracker. In some examples, pyrolysis oil from the steam cracker and / or heavy oil fractions from the gas oil hydrocracker are supplied as additional feed to the residue hydrocracker. In some examples, catalytic hydrocracking of unconverted oil products and vacuum residue fractions produces asphalt and marine residue fuel oil. In some examples, the marine residue fuel oil has a sulfur content of up to 0.5%.

[0062] Figure 1 This is a schematic illustration of a system 100 for processing crude oil 102 to produce more chemical feedstocks such as light olefins, lubricants, and fuels, according to embodiments of this disclosure. System 100 includes a crude oil distillation unit 104, a first diesel hydrocracking processor 124, a second diesel hydrocracking processor 136, a steam cracking zone 122, a fuel processing zone 134, a gas oil hydrocracker 144, a residue hydrocracker 154, and a lubricant production zone 150.

[0063] In some examples, the crude oil distillation unit 104 is configured to fractionate the crude oil feed 102 to produce a first naphtha minus product 106, a kerosene fraction 108, a light atmospheric gas oil fraction 110, a heavy atmospheric gas oil fraction 112, a light vacuum gas oil fraction 114, a medium vacuum gas oil fraction 116, a heavy vacuum gas oil fraction 118, and a vacuum residue fraction 120.

[0064] The crude oil distillation unit 104 is connected to and in fluid communication with at least two diesel hydrotreating processors 124 and 136. The first diesel hydrotreating processor 124 is configured to receive a first portion 126 of a kerosene fraction 108 and a light atmospheric gas oil fraction, and operates at a pressure less than about 40 bar gauge pressure to produce a first diesel product 132 and a second naphtha subtractive product 130. The first diesel hydrotreating processor 124 can operate at pressures from about 25 bar gauge pressure to about 40 bar gauge pressure. In some examples, the second naphtha subtractive product 130 is a crude naphtha fraction that undergoes fractionation downstream in a CDU stabilization unit to separate liquefied petroleum gas and naphtha. The second diesel hydrotreating processor 136 is configured to receive a second portion 128 of light atmospheric gas oil fraction and a light vacuum gas oil fraction 114, and operates at a pressure greater than about 60 bar gauge pressure to produce a first tail gas 138, a second diesel product 142, and a third naphtha subtractive product 140. In some examples, the second diesel hydrotreating processor 136 operates at a pressure from about 60 bar gauge pressure to about 80 bar gauge pressure. The first tail gas 138 may be supplied to a steam cracking zone 122, a fuel processing zone 134, or both. The second diesel product 142 and the third naphtha subtractive product 140 are supplied to the steam cracking zone 122 and the fuel processing zone 134, respectively.

[0065] The crude oil distillation unit 104 is connected to and in fluid communication with the gas oil hydrocracker 144. The gas oil hydrocracker 144 is configured to receive heavy atmospheric gas oil fraction 112, medium vacuum gas oil fraction 116, and heavy vacuum gas oil fraction 118 from the crude oil distillation unit 104, and to produce a first hydrocracking product 146, a base oil product 148, and an unconverted oil product 152 in the presence of a hydrocracking catalyst. The first hydrocracking product 146 may include a second tail gas, a fourth naphtha subtractive product, and / or a third diesel product, all of which may be supplied to the steam cracking zone 122 for the production of light olefins. In some examples, the second tail gas and the fourth naphtha subtractive product are supplied to the steam cracking zone 122. Base oil product 148 (which contains unconverted oil with high paraffin content) is supplied to lubricant production zone 150 or to steam cracking zone 122 for the production of light olefins. Lubricant production zone 150 may include selective hydrotreating, MTBE process and full hydrotreating.

[0066] Gas oil hydrocracker 144 is connected to and in fluid communication with residue hydrocracker 154 and lubricating oil production zone 150. Residue hydrocracker 154 is configured to receive unconverted oil product 152 from gas oil hydrocracker 144 and vacuum residue fraction 120 from crude oil distillation unit 104, and to produce a second hydrocracking product 156, a middle distillate product 158, and a heavy distillate product 160. Second hydrocracking product 156 comprises one or more of a third tail gas, a fifth naphtha subtractive product, and a fourth diesel product. In some examples, the third tail gas, the fifth naphtha subtractive product, and the fourth diesel product are all supplied to steam cracking zone 122 to produce light olefins. In some examples, the third tail gas and the fifth naphtha subtractive product are supplied to steam cracking zone 122 to produce light olefins, and the fourth diesel product is supplied to fuel processing zone 134 to produce fuel. This fuel is one or more of gasoline, jet fuel, and diesel fuel. The middle distillate product from residue hydrocracker 154 is recycled to the second diesel hydrocracker 136. The heavy distillate product from residue hydrocracker is supplied as recycle stream 162 to gas oil hydrocracker 144. In some examples, a first portion of the heavy distillate product 160 from residue hydrocracker 154 is supplied as recycle stream 162 to gas oil hydrocracker 144, and a second portion of the heavy distillate product from residue hydrocracker is supplied as feed stream 164 to lubricating oil production zone 150 to produce lubricating oil.

[0067] In some examples, pyrolysis oil from the steam cracker and / or heavy aromatics stream from the aromatics extraction unit are supplied to the residue hydrocracker 154 along with unconverted oil product 152. In some examples, a portion of the vacuum residue fraction 120 undergoes a solvent deasphalting process to produce deasphalted oil supplied to the gas oil hydrocracker. In some examples, pyrolysis oil from the steam cracker and / or heavy oil fraction from the gas oil hydrocracker are supplied as additional feed to the residue hydrocracker. In some examples, catalytic hydrocracking of unconverted oil product 152 and vacuum residue fraction 120 produces asphalt and marine residue fuel oil. In some examples, the marine residue fuel oil has a sulfur content of up to 0.5%.

[0068] When this document discloses a range, any lower bound can be combined with any upper bound to enumerate unenumerated ranges, and any lower bound can be combined with any other lower bound to enumerate unenumerated ranges; similarly, any upper bound can be combined with any other upper bound to enumerate unenumerated ranges. Furthermore, references to values ​​described within a range include every and all values ​​within that range, even if not explicitly enumerated. Therefore, each point or individual value can be used as its own lower or upper bound, combined with any other point or individual value or any other lower or upper bound, to enumerate unenumerated ranges.

[0069] Other objects, features, and advantages of the present invention will become apparent from the foregoing drawings, detailed descriptions, and embodiments. While these drawings, detailed descriptions, and embodiments illustrate specific embodiments of the invention, they are given by way of illustration only and are not intended to be limiting. In other embodiments, features from a specific embodiment may be combined with features from other embodiments. For example, a feature from one embodiment may be combined with features from any other embodiment. In other embodiments, additional features may be added to the specific embodiments described herein. It should be understood that although the present invention includes certain aspects, embodiments, and optional features, changes, modifications, or variations can be made to these aspects, embodiments, and optional features by those skilled in the art, and such changes, modifications, or variations are considered to be within the scope of the present invention.

Claims

1. A method for producing light olefins, lubricating oils, and fuels from crude oil feedstock, the method comprising: Fractionating crude oil feedstock produces naphtha minus products, kerosene fraction, light atmospheric gas oil fraction, heavy atmospheric gas oil fraction, light vacuum gas oil fraction, medium vacuum gas oil fraction, heavy vacuum gas oil fraction, and vacuum residue fraction. The first portion of the light atmospheric gas oil fraction and the kerosene fraction are hydrotreated at a pressure of less than about 40 bar gauge pressure to produce a first diesel product and a second naphtha subtractive product. The second portion of the light atmospheric gas oil fraction and the light vacuum gas oil fraction are hydrotreated at a pressure greater than about 60 bar gauge pressure to produce a second diesel product and a third naphtha subtractive product. The heavy atmospheric gas oil fraction and the medium vacuum gas oil fraction are split in the presence of a first hydrocracking catalyst to produce a fourth naphtha subtraction product, a third diesel product, a base oil product and an unconverted oil product. In the presence of a second hydrocracking catalyst, the unconverted oil and the vacuum residue are distilled to produce a fifth naphtha product, a fourth diesel product, a middle distillate product, and a heavy distillate product. The first naphtha subtractive product, the second naphtha subtractive product, the third naphtha subtractive product, the fourth naphtha subtractive product, and the fifth naphtha product are supplied to produce light olefins; The first diesel product, the second diesel product, the third diesel product, and the fourth diesel product are processed to produce fuel; as well as Base oil products and heavy distillate products from the gas oil hydrocracker are supplied to the lubricant production area to produce lubricants.

2. The method according to claim 1, further comprising: The middle distillate product is hydrotreated at a pressure greater than about 60 bar gauge pressure to produce the second diesel product and the third naphtha subtractive product.

3. The method according to claim 1, further comprising: The heavy distillate product is cracked in the presence of the first hydrocracking catalyst to produce the fourth naphtha subtractive product, the third diesel product, the base oil product, and the unconverted oil product.

4. The method according to claim 1, wherein, The first portion of the light atmospheric gas oil fraction and the kerosene fraction are hydrogenated in a pressure range of about 25 bar gauge pressure to about 40 bar gauge pressure.

5. The method according to claim 1, wherein, The second portion of the light atmospheric gas oil fraction and the light vacuum gas oil fraction are hydrogenated in a pressure range of about 60 bar gauge pressure to about 80 bar gauge pressure.

6. The method according to claim 1, further comprising: A portion of the vacuum residue fraction is fed to a solvent deasphalting unit to produce deasphalted oil before being supplied to the cracking process in the presence of the second hydrocracking catalyst.

7. The method according to claim 1, wherein, The lubricating oil production area includes selective hydrotreating, methyl tert-butyl ether process, and full hydrotreating.

8. A system for producing light olefins, lubricating oils, and fuels from crude oil feedstock, said system comprising: A crude oil distillation unit is configured to fractionate crude oil feedstock to produce first naphtha minus products, kerosene fraction, light atmospheric gas oil fraction, heavy atmospheric gas oil fraction, light vacuum gas oil fraction, medium vacuum gas oil fraction, heavy vacuum gas oil fraction, and vacuum residue fraction. A first diesel hydrotreating processor is in fluid communication with the crude oil distillation unit and is configured to receive a first portion of the light atmospheric gas oil fraction and the kerosene fraction to produce a first diesel product and a second naphtha subtractive product. A second diesel hydrotreating processor with dewaxing capability is in fluid communication with the crude oil distillation unit and configured to receive a second portion of the light atmospheric gas oil fraction and the light vacuum gas oil fraction to produce a second diesel product and a third naphtha subtractive product. Gas oil hydrocracker, which is in fluid communication with the crude oil distillation unit and configured to split the heavy atmospheric gas oil, the medium vacuum gas oil fraction and the heavy vacuum gas oil fraction to produce fourth naphtha subtractive products, third diesel products, base oil products and unconverted oil products; A residue hydrocracker, which is in fluid communication with the crude oil distillation unit and the gas oil hydrocracker and is configured to split the unconverted oil products and the vacuum residue distillate to produce a fifth naphtha product, a fourth diesel product, a middle distillate product and a heavy distillate product; A steam cracking zone, which is in fluid communication with the crude oil distillation unit, the first diesel hydrotreating unit, the second diesel hydrotreating unit, the gas oil hydrocracker and the residue hydrocracker, and is configured to crack the first naphtha subtractive product, the second naphtha subtractive product, the third naphtha subtractive product, the fourth naphtha subtractive product and the fifth naphtha product to produce light olefins; The fuel processing area is in fluid communication with the first diesel hydrotreating processor, the second diesel hydrotreating processor, the gas oil hydrocracker and the residue oil hydrocracker and is configured to process the first diesel product, the second diesel product, the third diesel product and the fourth diesel product to produce fuel. as well as The lubricating oil production area is in fluid communication with the gas oil hydrocracker and the residue oil hydrocracker and is configured to process the base oil products and the heavy distillate products to produce lubricating oil.

9. The system according to claim 8, further comprising: The solvent deasphalting unit is configured to receive a portion of the vacuum residue fraction and produce deasphalted oil and asphalt supplied to the gas oil hydrocracker.

10. The system according to claim 8, wherein, The gas oil hydrocracker is a fixed-bed cracker.

11. The system according to claim 8, wherein, The lubricating oil production area includes a selective hydrogenation unit, an MTBE production unit, and a full hydrogenation unit.

12. The system according to claim 8, wherein, The first diesel hydrorefueling processor operates at a pressure of less than approximately 40 bar gauge pressure.

13. The system according to claim 8, wherein, The second diesel hydrorefueling processor operates at a pressure greater than approximately 60 bar gauge pressure.

14. The system according to claim 8, wherein, The first diesel hydrorefueling processor operates in a pressure range of approximately 25 bar gauge pressure to approximately 40 bar gauge pressure.

15. The system according to claim 8, wherein, The second diesel hydrorefueling processor operates in a pressure range of approximately 60 bar gauge pressure to approximately 80 bar gauge pressure.

16. The system according to claim 8, wherein, The second diesel hydrocracking processor is also configured to receive medium distillate products from the residue hydrocracking unit.

17. The system according to claim 8, wherein, The gas oil hydrocracker is also configured to receive heavy distillate products from the residue hydrocracker.

18. The system according to claim 8, wherein, The residue hydrocracker is also configured to receive cracked oil from the second steam cracking unit.

19. The system according to claim 18, wherein, The pyrolysis oil is derived from a mixed plastic slurry.

20. The system according to claim 8, wherein, The residue hydrocracker is also configured to produce bitumen and marine residue fuel oil.

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