Process for improving base oil yield

Abstract

An improved process for manufacturing base oils and increasing base oil yield by combining a normal pressure resid feedstock and a base oil feedstock and by hydrogenation to form base oil products. The process generally involves subjecting a base oil feed stream comprising normal pressure resid to hydrocracking and dewaxing steps and optionally to hydrofinishing to produce light and heavy grade base oil products. Also disclosed is a process for manufacturing base oils having a viscosity index of 120 or more from a base oil feedstock having a viscosity index of about 100 or more, the base oil feedstock comprising a narrow cut point range vacuum gas oil. The invention can be used to manufacture Group II and / or Group III / III+ base oils, and in particular, to increase the yield of heavy base oil products relative to light base oil products produced in the process.

Description

[0001] This application is a divisional application of Chinese patent application filed on August 12, 2020, with application number 202080061522.6 and title "Process for Improving Base Oil Yield".

[0002] Cross-reference to related applications

[0003] This application claims priority to U.S. Provisional Patent Application No. 62 / 885,359, filed August 12, 2019, the entire disclosure of which is incorporated herein by reference. Technical Field

[0004] This invention relates to a process for increasing base oil yield by combining atmospheric residue feedstock with base oil feedstock to form a combined feed stream and forming base oil products from the combined feed stream by hydrogenation. Background Technology

[0005] 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 gas oil (VGO), by 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 crack into low-boiling molecules, which increases the VI but also decreases the viscosity. To produce high-VI and high-viscosity base oils in high yields, the hydrocracker feed must contain a certain amount of high-boiling molecules. Typically, due to practical limitations in temperature and pressure, the ability of VGO to recover high-boiling molecules from atmospheric residue (AR) in a vacuum column is limited. 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 asphaltenes. These materials shorten the hydrocracker catalyst lifetime to an unacceptable degree, making the use of this feed impractical.

[0006] One approach to using difficult whole crude oil and other intermediate feedstocks for base oil production is to first process the feedstock, such as AR or vacuum residue (VR), in a solvent deasphalting (SDA) unit. This processing is often necessary to separate most of the unwanted material while producing deasphalted oil (DAO) with acceptable hydrocracker feedstock quality. However, the very high capital requirements and operating costs of such SDA units, along with the overall processing method, make them an undesirable alternative. Other methods have been implemented that attempt to minimize or eliminate the need for the solvent deasphalting step, but have not offered significant benefits in terms of cost or other process improvements.

[0007] 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 techniques, such as gas-liquidation (GTL) feedstocks or, for example, multiple hydrocracking of mineral oils. The production of Group III base oils often also requires high-quality feedstocks and high-conversion processing, at the expense of product yield to meet Group VI targets. However, despite ongoing industry efforts, relatively inexpensive and suitable feedstocks, as well as simplified processes for manufacturing such products, remain to be developed and commercialized.

[0008] Despite progress in producing base oils from diverse and challenging feedstocks, improvements are still needed to optimize processes to utilize different feedstocks and increase the yield of valuable base oil products. Summary of the Invention

[0009] This invention relates to a process for producing base oil products, particularly light and heavy grades, by hydrogenating a base oil feed stream. While not necessarily limited thereto, one objective of this invention is to provide increased base oil yields for heavy grade base oil products and to produce Group II and / or Group III / III+ base oils.

[0010] Typically, the first process according to the invention comprises producing base oil by means of the following steps: combining atmospheric residue feedstock and base oil feedstock to form a base oil feed stream; contacting the base oil feed stream with a hydrocracking catalyst under hydrocracking conditions to form hydrocracking products; separating the hydrocracking products into gaseous and liquid fractions; contacting the liquid fraction with a dewaxing catalyst under hydroisomerization conditions to produce dewaxing products; and, optionally, contacting the dewaxing products with a hydrorefining catalyst under hydrorefining conditions to produce hydrorefined dewaxing products.

[0011] The present invention also relates to a method for modifying a base oil process by adding an atmospheric residue feedstock to a conventional base oil process. The method includes subjecting the base oil feedstream to hydrocracking and dewaxing steps to form dewaxed products, the dewaxing products comprising light and heavy products. Thus, the modified base oil process includes combining an atmospheric residue 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 hydrocracking products; separating the hydrocracking products into gaseous and liquid fractions; contacting the liquid fraction with a dewaxing catalyst under hydroisomerization conditions to produce dewaxed products; and, optionally, contacting the dewaxed products with a hydrorefining catalyst under hydrorefining conditions to produce hydrorefined dewaxed products.

[0012] A second process according to the invention comprises the following steps to produce a base oil with a viscosity index of 120 or higher: contacting a base oil feedstock with a viscosity index of about 100 or higher with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracking product, the base oil feedstock comprising medium vacuum gas oil (MVGO) with a front-end cut point of about 700℉ or higher and a rear-end cut point of about 900℉ or lower; separating the hydrocracking product into gas fractions and liquid fractions; dewaxing the liquid fraction to produce a dewaxed product; and optionally, hydrorefining the dewaxed product to produce a hydrorefined dewaxed product.

[0013] This invention also relates to a combined process for manufacturing base oil products from base oil feedstocks, the process combining a first process and a second process to manufacture base oils that meet Group II and / or Group III / III+ specifications. The combined process is typically used to manufacture base oils from base oil feedstocks or their fractions and includes: using an atmospheric residue fraction from the base oil feedstock or its fractions; separating the base oil feedstock or its fractions and / or the atmospheric residue fraction into narrow vacuum gas oil cut-point fractions with a front cut-point of about 700℉ or higher and a rear cut-point of about 900℉ or lower to form a medium vacuum gas oil (MVGO) fraction and a residual heavy VGO (HHVGO) fraction; using the HHVGO fraction as the atmospheric residue feedstock in the first process; and / or using the MVGO fraction as the base oil feedstock in the second process. Attached Figure Description

[0014] The scope of this invention is not limited by any representative figures accompanying this disclosure, and should be understood to be defined by the claims of this application.

[0015] Figure 1 It is a schematic diagram of the general process of existing technology for manufacturing base oil products.

[0016] Figure 2a This is a general block diagram of an embodiment of the process for manufacturing base oil products using a blend of VGO and atmospheric residue (VGO / AR) according to the present invention.

[0017] Figure 2b This is a general block diagram of an embodiment of the process for manufacturing Group III / III+ base oil products using MVGO fraction from atmospheric residue and for manufacturing Group II base oil products using a blend of VGO and HHVGO residue fraction from atmospheric residue (VGO / HHVGO).

[0018] Figure 3a This is a schematic diagram of an embodiment of the process for manufacturing base oil products according to the present invention, as described in the examples.

[0019] Figure 3b This is a schematic diagram of an embodiment of the process for manufacturing base oil products according to the present invention, as described in the examples.

[0020] Figure 4 This is a schematic diagram of an embodiment of the process for manufacturing base oil products according to the present invention, as described in the examples.

[0021] Figure 5 This is a schematic diagram of an embodiment of the process for manufacturing base oil products according to the present invention, as described in the examples. Detailed Implementation

[0022] Although illustrative embodiments of one or more aspects are provided herein, the disclosed process can be implemented using any number of techniques. This 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 may be made within the scope of the appended claims and their equivalents.

[0023] Unless otherwise stated, the following terms, specialized terms, and definitions apply to this disclosure. If a term is used in this disclosure but is not specifically defined herein, the definition from the IUPAC General Outline 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 claim to which the definition applies ambiguous or invalid. If any definition or usage provided by reference to any document incorporated herein conflicts with the definition or usage provided herein, it should be understood that the definition or usage provided herein applies.

[0024] "API Base Oil Categories" are base oil classifications that conform to the different standards shown in Table 1:

[0025] Table 1: Properties of Base Oil Feedstock (Feedstock with a viscosity of 4 cSt at 100℃, without additives)

[0026]

[0027] "API density" refers to the specific gravity of a petroleum feedstock or product relative to water, as determined by ASTM D4052-11 or ASTM D1298.

[0028] "ISO-VG" refers to the viscosity classification recommended for industrial applications, as defined in ISO 3448:1992.

[0029] "Viscosity index" (VI) indicates the temperature dependence of a lubricant, as determined by ASTM D2270-10 (E2011).

[0030] "Aromatic extraction" is part of a process used to produce solvent-neutral base oils. During aromatic extraction, vacuum gas oil, deasphalted oil, or mixtures thereof are extracted using a solvent extraction unit. After solvent evaporation, aromatic extraction produces a waxy raffinate and aromatic extract.

[0031] Atmospheric residue (AR) is the product of crude oil distillation at atmospheric pressure, in which volatile substances have been removed during distillation. AR fractions are typically derived at cut points of 650℉ to 680℉.

[0032] Vacuum gas oil (VGO) is a byproduct of crude oil vacuum distillation and can be sent to hydrotreating units or aromatics extraction units to upgrade the base oil. VGO typically consists of hydrocarbons with a boiling range between 343°C (649°F) and 538°C (1000°F) at 0.101 MPa.

[0033] "Deasphalted oil" (DAO) generally refers to residual oil from a vacuum distillation unit that has been deasphalted during solvent deasphalting. Solvent deasphalting in refineries is described in J. Speight's Synthetic Fuels Handbook, ISBN007149023Χ, 2008, pp. 64, 85-85, and 121.

[0034] When used in conjunction with oil feedstocks, “processed,” “treated,” “upgraded,” “refined,” and “refined” describe feedstocks that are undergoing or have undergone hydrogenation, or the resulting material or crude oil product, which reduces the molecular weight of the feedstock, lowers the boiling point range of the feedstock, reduces the concentration of asphaltenes, reduces the concentration of hydrocarbon free radicals, and / or reduces the amount of impurities such as sulfur, nitrogen, oxygen, halides, and metals.

[0035] Solvent dewaxing is a process that removes wax by crystallizing paraffin at low temperatures and then separating it through filtration. Solvent dewaxing produces dewaxed oil and soft wax. The dewaxed oil can be further hydrorefined to produce base oils.

[0036] "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.

[0037] "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 cyclic hydrocarbons (cycloalkanes) into acyclic branched alkanes.

[0038] "Hydrotreatment" refers to the process of converting sulfur- and / or nitrogen-containing hydrocarbon feedstocks into hydrocarbon products with reduced sulfur and / or nitrogen content. It is usually combined with hydrocracking and produces hydrogen sulfide and / or ammonia as byproducts.

[0039] "Catalytic dewaxing" or hydroisomerization refers to the process of isomerizing n-alkanes into their more branched counterparts in the presence of hydrogen and on a catalyst.

[0040] "Hydrorefining" refers to a process designed 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 typically considered holoc or turbid, or 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.

[0041] The term “hydrogen” or “hydrogen gas” refers to hydrogen itself and / or one or more compounds that provide a source of hydrogen.

[0042] The "cut-off point" refers to the temperature on the true boiling point (TBP) curve at which the predetermined degree of separation is achieved.

[0043] “TBP” refers to the boiling point of hydrocarbon feedstock or product, as determined by simulated distillation (SimDist) according to ASTM D2887-13.

[0044] "Hydrocarbon," "hydrocarbon," and similar terms refer to compounds containing only carbon and hydrogen atoms. Other identifiers may be used to indicate the presence of a specific group (if any) 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).

[0045] "Group IIB" or "Group IIB metals" refers to zinc (Zn), cadmium (Cd), mercury (Hg), and combinations thereof, in elemental, compound, or ionic form.

[0046] "Group IVA" or "Group IVA metals" refers to germanium (Ge), tin (Sn), or lead (Pb) and combinations thereof in elemental, compound, or ionic form.

[0047] "Group V metals" refers to vanadium (V), niobium (Nb), tantalum (Ta), and combinations thereof, in elemental, compound, or ionic form.

[0048] "Group VIB" or "Group VIB metals" refers to chromium (Cr), molybdenum (Mo), tungsten (W), and combinations thereof, in elemental, compound, or ionic form.

[0049] "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.

[0050] The term "support," particularly when used in the term "catalyst support," refers to a conventional material, typically a solid with a high surface area, to 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 aluminosilicates, zeolites, alumina-boron oxide, silica-alumina-magnesium oxide, silica-alumina-titanium oxide, and materials obtained by adding other zeolites and other complex oxides to the aforementioned materials.

[0051] "Molecular sieve" refers to a material with uniformly sized pores within its framework structure, such that, depending on the type of molecular sieve, only certain molecules can approach its pore structure, while others are excluded, for example, due to molecular size and / or reactivity. Zeolites, crystalline aluminophosphates, and crystalline silica aluminophosphates are representative examples of molecular sieves.

[0052] 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, while 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:

[0053]

[0054] In this disclosure, although compositions and methods or processes are generally described as “comprising” various components or steps, compositions and methods may also “consist substantially of various components or steps” or “comprise various components or steps”.

[0055] The terms “an,” “an,” and “the” are intended to include a plurality of alternatives, such as at least one. For example, unless otherwise stated, the disclosure of “transition metal” or “alkali metal” is intended to cover one or more of the transition metals or alkali metals, or mixtures or combinations thereof.

[0056] All numerical values ​​in the specific embodiments and claims have been modified to the values ​​indicated by “about” or “approximately”, and have taken into account experimental errors and variations expected by those skilled in the art.

[0057] In one aspect, the present invention is a process for manufacturing base oil products, including...

[0058] Atmospheric residue feedstock and base oil feedstock are combined to form a base oil feed stream;

[0059] The base oil feed stream is contacted with a hydrocracking catalyst under hydrocracking conditions to form hydrocracking products;

[0060] The hydrocracking products are separated into gaseous and liquid fractions;

[0061] The liquid fraction is contacted with a dewaxing catalyst under hydroisomerization conditions to produce a dewaxing product; and

[0062] Optionally, the dewaxed product is contacted with a hydrorefining catalyst under hydrorefining conditions to produce a hydrorefined dewaxed product.

[0063] The base oil feedstock typically meets one or more of the following property conditions:

[0064] The API density is in the range of 15-40, 15-30, or 15-25, or at least 15 or at least 17, optionally less than that of the atmospheric residue feedstock;

[0065] The VI is in the range of 30-90, 40-90, 50-90, or 50-80, and optionally, is less than the VI of the atmospheric residue feedstock;

[0066] 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;

[0067] The 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;

[0068] The asphalt content of hot C7 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;

[0069] 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 optionally, greater than the wax content of the base oil feedstock.

[0070] Nitrogen content is less than 2500 ppm, or less than 2000 ppm, or less than 1500 ppm, or less than 1000 ppm, or less than 500 ppm, or less than 200 ppm, or less than 100 ppm;

[0071] Sulfur content less than 8000 ppm, or less than 6000 ppm, or less than 4000 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, 100-6000 ppm, 100-4000 ppm, 100-2000 ppm, 100-1000 ppm, 100-500 ppm, or 100-200 ppm; and / or

[0072] The 1050+℉ content is in the range of 5-50% by weight, 5-40% by weight, or 8-40% by weight, or optionally, greater than the 1050+℉ content of the base oil feedstock.

[0073] 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, whole crude oils, and paraffinic crude oils from a variety of sources.

[0074] Atmospheric residue (AR) feedstock typically meets one or more of the following property conditions:

[0075] The API density is in the range of 20-60, 20-45, or 25-45, or at least 20 or at least 22, or optionally, greater than the API of the base oil feedstock;

[0076] The VI is in the range of 50-200, 70-190, or 90-180, or at least 80, or optionally, greater than the VI of the base oil feedstock;

[0077] 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;

[0078] The 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;

[0079] The asphalt content of hot C7 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.

[0080] 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 optionally, greater than the wax content of the base oil feedstock.

[0081] Nitrogen content is less than 2500 ppm, or less than 2000 ppm, or less than 1500 ppm, or less than 1000 ppm, or less than 500 ppm, or less than 200 ppm, or less than 100 ppm;

[0082] Sulfur content less than 8000 ppm, or less than 6000 ppm, or less than 4000 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, 100-6000 ppm, 100-4000 ppm, 100-2000 ppm, 100-1000 ppm, 100-500 ppm, or 100-200 ppm; and / or

[0083] The 1050+℉ content is in the range of 5-50% by weight, 5-40% by weight, or 8-40% by weight, or optionally, greater than the 1050+℉ content of the base oil feedstock.

[0084] In some respects, AR feedstocks possessing the properties described herein can be advantageously derived from light tight oils (LTOs, e.g., shale oils typically with an API >45). Suitable feedstocks can be Permian basin feedstocks and others, including Eagle Ford, Avalon, Magellan, Buckeye, etc.

[0085] Both base oil feedstocks and atmospheric residue feedstocks can possess any of the aforementioned properties within any of the broad and narrow ranges and combinations thereof.

[0086] The base oil feed stream typically consists of 10-60 wt% atmospheric residue feedstock and 40-90 wt% base oil feedstock, or 10-40 wt% atmospheric residue feedstock and 60-90 wt% base oil feedstock, or 10-30 wt% atmospheric residue feedstock and 70-90 wt% base oil feedstock, or 30-60 wt% atmospheric residue feedstock and 40-70 wt% base oil feedstock, or 40-60 wt% atmospheric residue feedstock and 40-60 wt% base oil feedstock.

[0087] In some implementations, the base oil feed stream contains no added crude oil feedstock, and / or no vacuum residue feedstock, and / or no deasphalted oil feedstock components, and / or contains only atmospheric residue feedstock and base oil feedstock.

[0088] While not limited to straight-run processes, the processes do not necessarily involve recycling liquid feedstock as part of a base oil feedstream or as one or both of atmospheric residue and base oil feedstocks. However, in some embodiments, recycling of one or more intermediate streams may be required.

[0089] The base oil feedstock may include, or consist primarily of, vacuum gas oil, or be composed of vacuum gas oil. The vacuum gas oil may be heavy vacuum gas oil obtained from vacuum gas oil, which has been fractionated into light and heavy fractions, wherein the cut-off temperature range for the heavy fraction is approximately 950–1050 °C. ℉ .

[0090] Dewaxing products and / or hydrorefined dewaxing products are typically obtained as light base oil products and heavy base oil products. Light base oil products typically have a nominal viscosity of 4-8 cSt or 5-7 cSt at 100°C, and / or heavy base oil products typically have a nominal viscosity of 10-14 cSt or 11-13 cSt at 100°C. 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 about 12 cSt at 100°C, or a combination thereof.

[0091] One of the advantages associated with this process compared to the same process that does not include atmospheric residue feedstock in the lubricating oil feedstream is that the yield of heavy base oil product relative to light base oil product can be increased by at least about 2 L vol.% or at least about 5 L vol.% (liquid volume %). In some embodiments, the yield of heavy base product can be increased by at least about 10 L vol.%, or at least about 20 L vol.%, or at least about 30 L vol.%, or at least about 40 L vol.% compared to the same process that does not include atmospheric residue feedstock in the base oil feedstream.

[0092] On the other hand, the present invention relates to a method for modifying conventional or existing base oil processes. Specifically, a base oil process comprising subjecting a base oil feedstream to hydrocracking and dewaxing steps to form a dewaxed product comprising both lighter and heavier products can be modified according to the invention by the following steps: combining atmospheric residue feedstock with base oil feedstock to form a base oil feedstream; and subjecting the base oil feedstream containing atmospheric residue feedstock to hydrocracking and dewaxing steps of a base oil process to produce a dewaxed product. Optionally, the dewaxed product can be further contacted with a hydrorefining catalyst under hydrorefining conditions to produce a hydrorefined dewaxed product.

[0093] The present invention also relates to a process for manufacturing base oils, comprising: contacting a base oil feedstock with a viscosity index of about 100 or higher with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracking product, wherein the base oil feedstock comprises vacuum gas oil with a front-end cut point of about 700℉ or higher and a rear-end cut point of about 900℉ or lower; 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 optionally, 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. The viscosity index of the dewaxing product and / or the hydrorefined dewaxing product may be 130 or higher after dewaxing, or 135 or higher after dewaxing, or 140 or higher after dewaxing. The viscosity index of the hydrocracking product may be at least about 135, 140, 145, or 150. The dewaxing product prepared by the process may be a Class III or Class III+ product.

[0094] Compared to using conventional VGO feedstock, vacuum gas oil (MVGO), referred to herein as medium vacuum gas oil (MVGO), with a front-end cut point of about 700℉ or higher and a back-end cut point of about 900℉ or lower, provides improved waxy product yields at Group III or III+ viscosities of MVGO at 4cSt 100°C, which is at least about 3 lvol. higher than the same process without MVGO as a base oil feedstock.

[0095] This invention also relates to a process combining two process aspects, i.e., wherein the feedstock is used to obtain a narrow cut-point fraction, and the same or different feedstocks are used for an atmospheric residue fraction. A combined process for producing base oil from a base oil feedstock or its fraction includes: providing an atmospheric residue fraction from a base oil feedstock or its fraction; separating the base oil feedstock or its fraction and / or the base oil atmospheric residue fraction into a narrow vacuum gas oil cut-point fraction with a front cut-point of about 700℉ or higher and a rear cut-point of about 900℉ or lower to form an MVGO fraction and a residual HHVGO fraction; using the HHVGO fraction as the atmospheric residue feedstock in the first process to prepare a dewaxed product and / or a hydrorefined dewaxed product; and / or using the MVGO fraction as the base oil feedstock in the second process to prepare a dewaxed product with a post-dewax viscosity index of 120 or higher and / or a hydrorefined dewaxed product. In some embodiments, the base oil feedstock may include tight oil, particularly light tight oil, or a fraction thereof. Narrow vacuum gas oil cut-point fractions can also be derived from atmospheric residue fractions, including atmospheric residue fractions derived from light tight oils.

[0096] Advantageously, fractionating AR feedstock into MVGO and HHVGO fractions provides the capability to produce Group III / III+ base oil products, while still allowing the HHVGO fraction to be used with conventional VGO base oil feedstocks to produce Group II base oil products. In some embodiments, using MVGO to produce Group III / III+ base oil products results in higher yields of these products.

[0097] Figure 2a The diagram schematically illustrates a method or process according to one embodiment of the invention, wherein conventional base oil hydrotreating, hydrocracking, hydrodewaxing, and hydrorefining process steps, conditions, and catalysts are used. (Compared with...) Figure 1 Compared with the existing base oil process diagram shown, Figure 2a This illustrates the use of feed co-blending of VGO and atmospheric residue (AR), where conventional processes typically use VGO base oil feedstock. Figure 2b Further explanation: AR feedstock is used to form medium-reduced vacuum gas oil fraction (MVGO) and heavy VGO fraction (HHVGO). The MVGO feedstream is used to produce Group III / III+ base oil products, while the HHVGO feedstream is combined with conventional VGO base oil feedstock to produce Group II base oil products.

[0098] Catalysts suitable for use as hydrocracking, dewaxing, and hydrorefining catalysts in said processes and methods and associated process conditions are described in numerous disclosures, 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 No. 0,987; No. 7,179,366; No. 7,229,548; No. 7,232,515; No. 7,288,182; No. 7,544,285; No. 7,615,196; No. 7,803,735; No. 7,807,599; No. 7,816,298; No. 7,838,696; No. 7,910,761; No. 7,931,799; No. 7,964,524; No. 7,964,525; No. 7,964,526; No. 8,058,203; No. 10,196,575; WO 2017 / 044210; and other publicly disclosed.

[0099] Catalysts suitable for hydrocracking include, for example, materials with hydro-dehydrogenation activity, along with an active cracking component support. Such catalysts are described in detail in numerous patents and literature references. Exemplary cracking component supports include silica-alumina, silica-zirconia composites, acid-treated clay, crystalline aluminosilicate zeolite molecular sieves (e.g., zeolite A, octahedral zeolite, zeolite X, and zeolite Y), and combinations thereof. The hydro-dehydrogenation component of the catalyst preferably includes metals 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 hydrocracking process steps are combinations of nickel-tungsten-silica-alumina, nickel-molybdenum-silica-alumina, and cobalt-molybdenum-silica-alumina. The hydrogenation and cracking activities of such catalysts, as well as their ability to maintain high activity over long-term use, depend on their composition and preparation.

[0100] Typical hydrocracking reaction conditions include, for example: temperature, 450℉ to 900℉ (232℃ to 482℃), such as 650℉ to 850℉ (343℃ to 454℃); pressure, 500 psig to 5000 psig (3.5 MPa to 34.5 MPa gauge pressure), such as 1500 psig to 3500 psig (10.4 MPa to 24.2 MPa gauge pressure); and liquid reactant feed rate in liquid space-time velocity (LHSV), 0.1 hr. -1 up to 15 hours -1 (v / v), for example, 0.25 hr -1 Up to 2.5 hours -1 Hydrogen feed rate, expressed as H2 / hydrocarbon ratio, for liquid base oil (lubricant) feedstock, ranging from 500 SCF / bbl to 5000 SCF / bbl (89 to 890 m). 3 H2 / m 3 (raw material); and / or hydrogen partial pressure, greater than 200 psig, for example 500 to 3000 psig; and hydrogen recirculation rate, greater than 500 SCF / B, for example between 1000 SCF / B and 7000 SCF / B.

[0101] Hydrodewaxing is primarily used to lower the pour point and / or cloud point of base oils by removing wax from them. Typically, dewaxing involves a catalytic process to treat the wax, and the dewaxing feed is usually upgraded prior to dewaxing to increase its viscosity index, reduce aromatic and heteroatom content, and decrease the amount of low-boiling components in the feed. Some dewaxing catalysts complete the wax conversion reaction by cracking wax-containing molecules into lower molecular weight molecules. Other dewaxing processes can convert the wax contained in the hydrocarbon feed into isomerized molecules by wax isomerization to produce isomerized molecules with pour points lower than their non-isomerized counterparts. As used herein, isomerization includes hydroisomerization processes, which use hydrogen in the isomerization of wax molecules under catalytic hydroisomerization conditions.

[0102] Dewaxing typically involves treating the dewaxing feedstock with hydroisomerization to at least convert n-alkanes and form isomerization products including isoalkanes. Suitable isomerization catalysts for 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-4 3. SSZ-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, 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 (e.g., β or zeolite Y molecular sieves, silica, alumina, silica-alumina, and combinations thereof). Suitable isomerization catalysts are described in detail in patent literature, see, for example, U.S. Patents 4,859,312; 5,158,665; and 5,300,210.

[0103] Hydrodewaxing conditions typically depend on the feedstock, catalyst, whether the catalyst is sulfurized, the desired yield, and the properties of the base oil. Typical conditions include: temperatures ranging from 500℉ to 775℉ (260℃ to 413℃); pressures ranging from 15 psig to 3000 psig (0.10 MPa to 20.68 MPa gauge pressure); and a duration of 0.25 hr. -1 up to 20 hr -1 LHSV; 2000 SCF / bbl to 30,000 SCF / bbl (356 to 5340 m 3 H2 / m 3 The hydrogen-to-feed ratio is [value missing]. Typically, the hydrogen will be separated from the product and recycled to the isomerization zone. Suitable dewaxing conditions and processes are described, for example, in U.S. Patents 5,135,638; 5,282,958; and 7,282,134.

[0104] Waxed products W220 and W600 can be dewaxed to form 220N and 600N products, which may be suitable (or better suited) for use as lubricating base oils or in lubricant formulations. For example, dewaxing products can be blended or mixed with existing lubricating base oils to produce new base oils or improve the properties of existing base oils, for example, to meet specific target conditions, such as viscosity or Noack target conditions, for specific base oil grades like 220N and 600N. Isomerization and blending can be used to adjust and maintain the pour point and cloud point of the base oils at suitable values. n-Alkanes can also be blended with other base oil components before undergoing catalytic isomerization, including blending n-alkanes with isomerization products. Lubricating base oils that can be produced in the dewaxing step can be treated in a separation step to remove light products. Lubricating base oils can be further processed by distillation, using atmospheric distillation, and optionally vacuum distillation to produce lubricating base oils.

[0105] Typical hydrotreating conditions vary over a wide range. Generally, the total LHSV is approximately 0.25 hr. -1 up to 10 hours -1 (v / v), or approximately 0.5 hr -1 Up to 1.5 hours -1 Total pressure ranges from 200 psig to 3000 psig, or from approximately 500 psia to approximately 2500 psia. Hydrogen feed rates, in H2 / hydrocarbon ratios, are typically 500 SCF / BBL to 5000 SCF / BBL (89 to 890 m³ / min). 3 H2 / m 3The raw materials are typically between 1000 SCF / Bbl and 3500 SCF / Bbl. The reaction temperature in the reactor is typically in the range of about 300℉ to about 750℉ (about 150°C to about 400°C), or in the range of 450℉ to 725℉ (230°C to 385°C).

[0106] In practice, stratified catalyst systems, including hydrotreatment (HDT, HDM, DEMET, etc.), hydrocracking (HCR), hydrodewaxing (HDW), and hydrorefining (HFN) catalysts, can be used to produce intermediate and / or finished base oils using single or multi-reactor systems. A typical configuration includes two reactors, the first of which contains a stratified catalyst providing DEMET, HDT pretreatment, HCR, and / or HDW activity. Different catalysts performing similar functions, such as different levels of hydrocracking activity, can also be used, for example, in different layers within a single reactor or in separate reactors.

[0107] Example

[0108] Samples of vacuum gas oil (VGO) and atmospheric residue (AR) were obtained from commercially available sources and Figure 3a , Figure 3b , Figure 4 and Figure 5 Used in the process scheme shown. Figure 3a and Figure 3b This illustrates a large process research facility configuration typically used to evaluate a large amount of available raw materials. Figure 4 and Figure 5 This demonstrates a small-scale laboratory apparatus for evaluating small amounts of raw materials and primarily for evaluating all AR samples.

[0109] The process conditions of the research apparatus used included 0.5 LHSV. -1 The reactor H2 partial pressure was 1750 psia, the hydrogen-to-gas-oil (recirculation) ratio was 4500 scfb, and the reactor temperature was maintained in the range of 700-770+℉. The temperature of the downstream reactor R2 was kept 20℉ higher than that of the upstream reactor R1. A rising temperature profile was applied, with ΔT values ​​of 120℉ and 40℉ for R1 and R2, respectively. The target viscosity index (VI) for the waxy product was set at 109 as 6.0 cSt (W220) at 100℃ and 11.8 cSt (W600) at 100℃.

[0110] The laboratory-scale process conditions used included 0.5 LHSV. -1The reactor pressure was 1850 psig, the hydrogen feed gas-oil ratio was 4500 scfb, and the reactor temperature was in the range of 700-770+℉. The temperature of the downstream reactor R2 was maintained 20℉ higher than that of the upstream reactor R1. The target viscosity index (VI) for the waxy product was set at 109 as 6.1 cSt (220R) at 100°C and 11.8 cSt (600R) at 100°C.

[0111] Catalyst loading in each reactor R1 and R2 (according to) Figure 3a , Figure 3b , Figure 4 and Figure 5 Each of these (R1 and R2) represents a conventional approach for base oil production, including stratified hydrometallization, hydrotreatment, and hydrocracking catalysts. A typical configuration includes a stratified catalyst system comprising one or more DEMET layers for both R1 and R2, a highly active HCR / HDT, an HCR, and a less active HCR catalyst.

[0112] Figure 3a , Figure 3b , Figure 4 and Figure 5 The feed stream 10 and H2 inlet 11 of each reactor R1 and R2 are shown, as well as other intermediate streams 20, 30, H2 recirculation stream 31, and whole liquid product (WLP) stream 32, which are fed to separators and / or condensers (C1 to C4, S1 and V3) to provide the corresponding product streams C2B, C3B, C4O, C4B, STO, STB, V3O and V3B shown in the figures and illustrated in the examples below.

[0113] Example 1 - Vacuum Gas Oil (VGO) Feedstock (Comparative Feedstock)

[0114] Samples of vacuum gas oil (VGO) feedstock from commercially available sources for the production of base oil products were obtained and analyzed as comparative baseline cases. Figure 3a , Figure 3b , Figure 4 and Figure 5 The process configuration shown below uses VGO feedstock in the following examples. The properties of this VGO feedstock (sample ID 2358) are shown in Table 1.

[0115] Table 1 - Properties of Vacuum Gas Oil (VGO) Feedstock

[0116]

[0117] Example 2 - Properties of Atmospheric Residue (AR) Feedstock

[0118] Samples of atmospheric residue oil (AR1 to AR5) from commercially available sources were obtained and analyzed. The properties of these AR samples used as feedstock components according to the invention are shown in Table 2.

[0119] Table 2 - Properties of Atmospheric Residue (AR) Feedstock

[0120]

[0121] Example 3 - Properties of blends of atmospheric residue (AR) feedstock and vacuum gas oil (VGO) feedstock

[0122] Samples of atmospheric residue oil AR1 to AR5 from Example 2 were blended with vacuum gas 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 feedstocks according to the present invention are shown in Table 3.

[0123] Table 3 - Properties of blends of atmospheric residue (AR) and vacuum gas oil (VGO) feedstocks

[0124]

[0125] Example 4 - Evaluation of Group II base oil production from blends of atmospheric residue (AR) and vacuum gas oil (VGO) feedstocks

[0126] According to Figure 3b For Group II base oil production using representative processes, evaluation samples AR1 to AR5 of atmospheric residue and vacuum gas oil (VGO) blends from Example 3 were used. The VGO feedstock from Example 1 (based on...) Figure 3a The process also yielded Class II results for comparison.

[0127] The laboratory-scale process conditions used included 0.5 LHSV. -1 The reactor pressure was 1850 psig, the hydrogen feed gas-oil ratio was 4500 scfb, and the reactor temperature was in the range of 700-770+℉. The temperature of the downstream reactor R2 was maintained 20℉ higher than that of the upstream reactor R1. The target viscosity index (VI) for the waxy product was set at 109 as 6.1 cSt (220R) at 100°C and 11.8 cSt (600R) at 100°C.

[0128] The base oil production results of AR1 / VGO blends compared to VGO feedstocks alone are shown in Table 4a, the results of blends of AR2 and AR3 with VGO are shown in Table 4b, and the results of blends of AR4 and AR5 with VGO are shown in Table 4c. Each set of results was determined using the AR / VGO blends of Example 3.

[0129] As shown in Table 4a, using the AR1 / VGO blend as a feedstock for the lubricating oil process resulted in a 57.5 vol% increase in W600 yield for heavy base oil, compared to 19.3 vol% when the feedstock did not include the atmospheric residue AR1 component. Although the AR1 / VGO blend exhibited some hydrocracking losses (~15℉) and HDN activity losses (19℉ or higher), this increase in heavy base oil yield was significant. The advantage of the high W600 yield suggests that a more active and stable HDN catalyst system would also be beneficial, particularly for high-nitrogen feedstocks.

[0130] Table 4a – Base Oil Production of AR1 / VGO (wt / wt) Blends

[0131]

[0132]

[0133]

[0134] Table 4b shows the results obtained for atmospheric residue samples AR2 and AR3, each blended with vacuum gas oil (VGO). As shown, if the same W220 VI (109 or close) is targeted, the AR2 / VGO blend (90-326-3242-3266) shows a significant improvement in both actual waxy W600 yield and total actual waxy yield: 36.6% vs. 18.6% for waxy W600R and 69.4% vs. 53.5% for total waxy yield. Although a higher waxy product nitrogen content was obtained, this high product nitrogen content is reduced, as shown in 90-326-3098-3122, at the cost of sacrificing waxy W600R yield and total waxy base oil yield (6% reduction for W600R and 2% reduction for total waxy base oil).

[0135] As shown in Table 4b, the AR3 / VGO blend (88-342-3726-3750) exhibits a significant increase in actual waxy W600R yield, at 31.9% vs. 18.6%, compared to VGO feed alone. The actual total waxy base oil yield remains unchanged, while the waxy product from the AR3 / VGO blend shows a slightly higher nitrogen content.

[0136] Table 4c shows the results obtained for atmospheric residue samples AR4 and AR5, each blended with vacuum gas oil (VGO). As shown, two separate tests were performed at different hydrocracking severities for each of the VGO control feed and the AR4 / VGO and AR5 / VGO blends.

[0137] Table 4b - Base Oil Production from AR2 / VGO and AR3 / VGO (wt / wt) Blends

[0138]

[0139] Table 4c - Base oil production from AR4 / VGO and AR5 / VGO (wt / wt) blends

[0140]

[0141] The results from Table 4c provide a basis for comparing waxy base oil yields at a viscosity index (VI) of 109 for W220 of AR2 / VGO, AR4 / VGO, and AR5 / VGO blends, as shown in Table 4d. At a W220 VI of 109, the waxy base oil yield of the 50% AR2 / VGO blend feed is 33.7% higher than that of the VGO feed excluding atmospheric residue AR2 components, compared to a W600 yield of 25.8%. The overall waxy base oil yield of the AR2 / VGO blend is 68.7%, while the overall waxy base oil yield of the feed excluding AR2 blend components is 66.1%.

[0142] The 20% AR4 / VGO blend also showed the following: the W600 yield of the AR4 / VGO blend was higher than that of the VGO feed itself (28.4% vs. 25.8%), the W220 yield of the AR4 / VGO blend was higher than that of the VGO feed itself (42.9% vs. 40.3%), and the overall waxy base oil yield of the AR4 / VGO blend was higher than that of the VGO feed itself (71.3% vs. 66.1%).

[0143] Similarly, 20% AR5 / VGO showed the following: the W220 yield of the AR5 / VGO blend was higher than that of the VGO feed itself (44.4% vs. 40.3%), and the total waxy base oil W600 yield of the AR5 / VGO blend was higher than that of the VGO feed itself (68.1% vs. 66.1%).

[0144] Table 4d - Comparison of yields of atmospheric residue / vacuum gas oil (AR / VGO) blends

[0145]

[0146] Example 5 - Evaluation of Atmospheric Residue (AR) to provide intermediate vacuum gas oil (MVGO) for Group III / III+ base oil production.

[0147] Atmospheric residue (AR) samples were evaluated to provide intermediate vacuum gas oil (MVGO) for the production of Group III / III+ base oils. MVGO samples were derived from the corresponding AR samples as distillation fractions within the following ranges: AR2 fraction width 717–876℉; AR4 fraction width 725–882℉; and AR5 fraction width 716–882℉. Table 5a presents the properties of AR samples AR2, AR4, and AR5, and the corresponding MVGO derivative fractions MVGO2, MVGO4, and MVGO5. Comparative properties of vacuum gas oil (VGO) are also included.

[0148] Will Figure 4 The process configurations were used to produce Group III base oils at different dewaxing severity levels to evaluate three atmospheric residue (AR) derived MVGOs with different wax viscosity indices (VI) at a kinematic viscosity (KV100) of approximately 4 cSt at 100°C. Table 5b summarizes the comparative cases of VGOs themselves and the yields of MVGOs derived from AR2, AR4, and AR5 feedstocks (designated as MVGO2, MVGO4, and MVGO5 feedstocks, respectively).

[0149] Table 5a - Properties of Atmospheric Residue (AR) and MVGO Feedstocks

[0150]

[0151] Table 5b - Comparison of VGO and MVGO feedstock yields for Group III base oil production

[0152]

[0153] Example 6 - Evaluation of Medium Vacuum Gas Oil (MVGO) Fraction Derived from Atmospheric Residue Feed AR3

[0154] Samples of atmospheric residue feedstock AR3 were evaluated to provide intermediate vacuum gas oil (MVGO) for the production of Group III / III+ base oils. MVGO samples were derived from the corresponding AR3 samples as distillation fractions and designated as MVGO3b in the range of 725-895℉. Width Temperature range fraction), designated as MVGO3n in the range of 725-855℉. narrow Temperature range (distillation fraction).

[0155] Table 6 presents the results of using MVGO3b and MVGO3n feeds for... Figure 3aThe results of the process configuration for producing Group III 4cSt base oils are presented. The properties of vacuum gas oil (VGO) are also compared. Both MVGO feedstocks MVGO3b and MVGO3n provide increased yields of waxy Group III products for 4cSt base oil production, with the wide-range MVGO3b showing a 4.5 l vol.% increase and the narrow-range MVGO3n showing a 6.6 l vol.% increase compared to using VGO feedstock.

[0156] Table 6 - MVGO for Group III 4 cSt base oil production

[0157]

[0158] Example 7 - Evaluation of the use of heavy vacuum gas oil (HHVGO) fraction derived from atmospheric residue (AR) for the production of Group II base oils.

[0159] As illustrated in Example 5, an atmospheric residue (AR) sample was used to provide medium-grade vacuum gas oil (MVGO) for the production of Group III / III+ base oils. The remaining fractions, lacking MVGO, were designated as HHVGO fractions. These HHVGO fractions were evaluated for use as feed components in blending with vacuum gas oil (VGO) to produce Group II base oils.

[0160] Table 7a presents the properties of HHVGO samples HHVGO2, HHVGO4, and HHVGO5, as well as blends of 9% HHVGO / VGO and 9% HHVGO / VGO. The properties of the comparative VGO feed are also shown.

[0161] Table 7a - Properties of HHVGO fraction and HHVGO / VGO blends

[0162]

[0163] Table 7b presents the use of HHVGO / VGO blend feed for... Figure 5 The results of the process configuration for producing Group II base oils are presented. Results comparing the process with vacuum gas oil (VGO) are also included. The results are further summarized in Table 7c. Both HHVGO feedstocks, namely 9% HHVGO2 / VGO and 9% HHVGO4 / VGO, provide comparable yields of waxy Group II base oil products compared to using VGO feedstock alone. Therefore, the combination of using MVGO fractions to produce Group III base oils and using the remaining HHVGO fractions to produce Group II base oils offers technical and economic advantages compared to using vacuum gas oil feedstocks.

[0164] Table 7b - Waxy base oil yield from HHVGO / VGO blend feed

[0165]

[0166] Table 7b (continued) - Waxy base oil yield from HHVGO / VGO blend feed

[0167]

[0168] Table 7c - Comparison of HHVGO / VGO blend feed yields at 109 VI W220

[0169]

[0170] The above description of one or more embodiments of the present invention is primarily for illustrative purposes, and it should be recognized that variations may be used that still encompass the essence of the invention. The following claims should be referenced in determining the scope of the invention.

[0171] For the purposes of U.S. patent practice, and in other permitted patent offices, all patents and publications referenced in the foregoing description of this invention are incorporated herein by reference, provided that any information contained therein is consistent with and / or supplements the foregoing disclosure.

[0172] In particular, the present invention also relates to the following items.

[0173] Project 1. A process for manufacturing base oils, comprising:

[0174] Atmospheric residue feedstock and base oil feedstock are combined to form a base oil feed stream;

[0175] The base oil feed stream is contacted with a hydrocracking catalyst under hydrocracking conditions to form hydrocracking products;

[0176] The hydrocracking products are separated into gaseous and liquid fractions;

[0177] The liquid fraction is contacted with a dewaxing catalyst under hydroisomerization conditions to produce a dewaxing product; and

[0178] Optionally, the dewaxed product is contacted with a hydrorefining catalyst under hydrorefining conditions to produce a hydrorefined dewaxed product.

[0179] Project 2. The process as described in Project 1, wherein the atmospheric residue feedstock meets one or more of the following conditions:

[0180] The API density is in the range of 20-60, 20-45, or 25-45, or at least 20 or at least 22, or optionally, greater than the API of the base oil feedstock;

[0181] The VI is in the range of 50-200, 70-190, or 90-180, or at least 80, or optionally, greater than the VI of the base oil feedstock;

[0182] 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;

[0183] The 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;

[0184] The asphalt content of hot C7 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;

[0185] 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 optionally, greater than the wax content of the base oil feedstock.

[0186] Nitrogen content is less than 2500 ppm, or less than 2000 ppm, or less than 1500 ppm, or less than 1000 ppm, or less than 500 ppm, or less than 200 ppm, or less than 100 ppm;

[0187] Sulfur content less than 8000 ppm, or less than 6000 ppm, or less than 4000 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, 100-6000 ppm, 100-4000 ppm, 100-2000 ppm, 100-1000 ppm, 100-500 ppm, or 100-200 ppm; and / or

[0188] The 1050+℉ content is in the range of 5-50% by weight, 5-40% by weight, or 8-40% by weight, or optionally, greater than the 1050+℉ content of the base oil feedstock.

[0189] Project 3. The process as described in any one of Projects 1-2, wherein the base oil feedstock meets one or more of the following conditions:

[0190] The API density is in the range of 15-40, 15-30, or 15-25, or at least 15 or at least 17, optionally less than that of the atmospheric residue feedstock;

[0191] The VI is in the range of 30-90, 40-90, 50-90, or 50-80, and optionally, is less than the VI of the atmospheric residue feedstock;

[0192] 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;

[0193] The 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;

[0194] The asphalt content of hot C7 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;

[0195] 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 optionally, greater than the wax content of the base oil feedstock.

[0196] Nitrogen content is less than 2500 ppm, or less than 2000 ppm, or less than 1500 ppm, or less than 1000 ppm, or less than 500 ppm, or less than 200 ppm, or less than 100 ppm;

[0197] Sulfur content less than 8000 ppm, or less than 6000 ppm, or less than 4000 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, 100-6000 ppm, 100-4000 ppm, 100-2000 ppm, 100-1000 ppm, 100-500 ppm, or 100-200 ppm; and / or

[0198] The 1050+℉ content is in the range of 5-50% by weight, 5-40% by weight, or 8-40% by weight, or optionally, greater than the 1050+℉ content of the base oil feedstock.

[0199] Project 4. The process as described in any one of Projects 1-3, wherein the base oil feedstock comprises 10-60 wt% atmospheric residue feedstock and 40-90 wt% base oil feedstock, or 10-40 wt% atmospheric residue feedstock and 60-90 wt% base oil feedstock, or 10-30 wt% atmospheric residue feedstock and 70-90 wt% base oil feedstock, or 30-60 wt% atmospheric residue feedstock and 40-70 wt% base oil feedstock, or 40-60 wt% atmospheric residue feedstock and 40-60 wt% base oil feedstock.

[0200] Project 5. The process as described in any one of Projects 1-4, wherein the base oil feed stream does not contain any added crude oil feedstock, or wherein the base oil feed stream does not contain vacuum residue feedstock, or wherein the base oil feed stream does not contain deasphalted oil, or wherein the base oil feed stream contains only atmospheric residue feedstock and base oil feedstock.

[0201] Item 6. The process as described in any one of Items 1-5, wherein the process does not include recycling the liquid feedstock as part of the base oil feed stream or as one or both of the atmospheric residue feedstock and the base oil feedstock.

[0202] Item 7. The process as described in any one of Items 1-6, wherein the base oil feedstock comprises vacuum gas oil or vacuum gas oil, or is substantially composed of vacuum gas oil, or is composed of vacuum gas oil.

[0203] Project 8. The process described in Project 7, wherein the vacuum gas oil is a heavy vacuum gas oil obtained from vacuum gas oil, the heavy vacuum gas oil being cut into light fractions and heavy fractions, wherein the cutting point temperature range of the heavy fraction is approximately 950-1050℉.

[0204] Project 9. The process of any one of Projects 1-8, wherein the dewaxing product and / or the hydrorefining dewaxing product are obtained as light base oil products and heavy base oil products.

[0205] Item 10. The process described in Item 9, wherein the nominal viscosity of the light base oil product at 100°C is in the range of 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 10-14 cSt or 11-13 cSt.

[0206] Item 11. The process as described in any one of Items 9-10, wherein, compared with the same process in which the atmospheric residue feedstock is not included in the base oil feedstream, the yield of the heavy base oil product relative to the light base oil product is increased by at least about 2 L / v or at least about 5 L / v.

[0207] Item 12. The process as described in any one of Items 9-11, wherein the overall waxy base oil yield is increased by at least about 2 L / v or at least about 5 L / v compared to the same process in which the atmospheric residue feedstock is not included in the base oil feed stream.

[0208] Item 13. The process of any one of Items 1-10, wherein the dewaxing product is further separated into a lighter product having a nominal viscosity of at least 6 cSt at 100°C, or a heavier product having a nominal viscosity of at least 12 cSt at 100°C, or a combination of both.

[0209] Item 14. A method for modifying a base oil process, wherein the base oil process includes subjecting a base oil feed stream to hydrocracking and dewaxing steps to form a dewaxed product comprising light and heavy products; the method includes,

[0210] Combining atmospheric residue feedstock and base oil feedstock to form the base oil feed stream; and

[0211] The base oil feed stream, which includes the atmospheric residue feedstock, is subjected to the hydrocracking and dewaxing steps of the base oil process.

[0212] The modified base oil process includes:

[0213] Atmospheric residue feedstock and base oil feedstock are combined to form a base oil feed stream;

[0214] The base oil feed stream is contacted with a hydrocracking catalyst under hydrocracking conditions to form hydrocracking products;

[0215] The hydrocracking products are separated into at least gaseous and liquid fractions;

[0216] The liquid fraction is contacted with a dewaxing catalyst under hydroisomerization conditions to produce a dewaxing product; and

[0217] Optionally, the dewaxed product is contacted with a hydrorefining catalyst under hydrorefining conditions to produce a hydrorefined dewaxed product.

[0218] Project 15. A process for manufacturing base oils, comprising:

[0219] Under hydrocracking conditions, a base oil feedstock with a viscosity index of about 100 or higher is contacted with a hydrocracking catalyst to form hydrocracking products, wherein the base oil feedstock includes vacuum gas oil with a front-end cut point of about 700℉ or higher and a rear-end cut point of about 900℉ or lower.

[0220] The hydrocracking products are separated into gaseous and liquid fractions;

[0221] The liquid fraction is contacted with a dewaxing catalyst under hydroisomerization conditions to produce a dewaxing product; and

[0222] Optionally, the dewaxed product is contacted with a hydrorefining catalyst under hydrorefining conditions to produce a hydrorefined dewaxed product;

[0223] Wherein, the viscosity index of the dewaxed product and / or the hydrorefined dewaxed product is 120 or higher after dewaxing.

[0224] Item 16. The process as described in Item 15, 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.

[0225] Item 17. The process as described in Item 15, wherein the dewaxing product and / or the hydrorefining dewaxing product comprises Group III or Group III+ base oil products.

[0226] Item 18. The process as described in Item 15, wherein the viscosity index of the hydrocracking product is at least about 135 or 140 or 145 or 150.

[0227] Item 19. The process of any one of Items 15-18, wherein the yield of waxy product of vacuum gas oil with a front-end cut point of about 700℉ or higher and a rear-end cut point of about 900℉ or lower at a viscosity of 4 cSt at 100°C is at least about 3 l higher by volume than that of the same process excluding vacuum gas oil with a front-end cut point of about 700℉ or higher and a rear-end cut point of about 900℉ or lower as the base oil feedstock.

[0228] Item 20. A process for producing base oils from base oil feedstocks or their fractions, the process comprising:

[0229] Atmospheric residue fractions are provided from base oil feedstocks or their fractions;

[0230] The base oil feedstock or its fraction and / or the atmospheric residue fraction of the base oil are separated into vacuum gas oil cut-point fractions with a front cut-point of about 700℉ or higher and a rear cut-point of about 900℉ or lower, to form medium vacuum gas oil MVGO fraction and heavy vacuum gas oil HHVGO fraction.

[0231] The HHVGO fraction is used as the atmospheric residue feedstock in the process described in Project 1; and / or

[0232] The MVGO fraction is used as the base oil feedstock in the process described in Project 14.

[0233] Item 21. The process as described in Item 20, wherein the base oil feedstock comprises tight oil or a fraction thereof.

[0234] Project 22. The process as described in Project 21, wherein the reduced pressure gas oil cut-point fraction is derived from the atmospheric residue fraction of the tight oil.

Claims

1. A process for manufacturing base oils, comprising: Atmospheric residue feedstock and base oil feedstock are combined to form a base oil feed stream; The base oil feed stream is contacted with a hydrocracking catalyst under hydrocracking conditions to form hydrocracking products; The hydrocracking products are separated into gaseous and liquid fractions; The liquid fraction is contacted with a dewaxing catalyst under hydroisomerization conditions to produce a dewaxing product; as well as Optionally, the dewaxed product is contacted with a hydrorefining catalyst under hydrorefining conditions to produce a hydrorefined dewaxed product. The atmospheric residue feedstock described herein meets one or more of the following conditions: API severity is in the range of 20-45; VI is in the range of 90-180; The viscosity at 100℃ is in the range of 3-20 cSt; The viscosity at 70℃ is in the range of 5-20 cSt; The asphalt content of hot C7 is in the range of 0.02-0.15% by weight; The wax content is in the range of 5-40% by weight; Nitrogen content less than 1500 ppm; Sulfur content less than 6000 ppm; and / or The content of 1050+℉ is in the range of 5-40% by weight. The base oil feedstock described herein meets one or more of the following conditions: API severity is in the range of 15-40; VI is in the range of 30-90; The viscosity at 100℃ is in the range of 3-30 cSt; The viscosity at 70℃ is in the range of 5-25 cSt; The asphalt content of hot C7 is in the range of 0.01-0.3% by weight; The wax content is in the range of 5-40% by weight; Nitrogen content less than 2500 ppm; Sulfur content less than 8000 ppm; and / or The content of 1050+℉ is in the range of 5-50% by weight.

2. The process of claim 1, wherein the atmospheric residue feedstock satisfies one or more of the following conditions: The API weight is in the range of 25-45, or at least 20 or at least 22, or optionally, greater than the API of the base oil feedstock; The VI is at least 80, or optionally, greater than the VI of the base oil feedstock; The viscosity at 100°C is at least 3 cSt or at least 4 cSt; The viscosity at 70°C is in the range of 5-15 cSt, or at least 5 cSt or at least 6 cSt; The hot C7 asphalt content is less than 0.3% by weight or less than 0.2% by weight. The wax content is in the range of 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 optionally, greater than the wax content of the base oil feedstock. Nitrogen content is less than 1000 ppm, or less than 500 ppm, or less than 200 ppm, or less than 100 ppm; Sulfur content less than 4000 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, 100-6000 ppm, 100-4000 ppm, 100-2000 ppm, 100-1000 ppm, 100-500 ppm, or 100-200 ppm; and / or The 1050+℉ content is in the range of 8-40% by weight, or optionally, greater than the 1050+℉ content of the base oil feedstock.

3. The process according to any one of claims 1-2, wherein the base oil feedstock satisfies one or more of the following conditions: The API density is in the range of 15-30 or 15-25, or at least 15 or at least 17, optionally less than that of the atmospheric residue feedstock; The VI is in the range of 40-90, 50-90, or 50-80, optionally less than the VI of the atmospheric residue feedstock; Viscosity at 100°C is in the range of 3-25 cSt or 3-20 cSt, or at least 3 cSt or at least 4 cSt; The viscosity at 70°C is in the range of 5-20 cSt or 5-15 cSt, or at least 5 cSt or at least 6 cSt; The asphalt content of hot C7 is in the range of 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 5-30% 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 optionally, greater than the wax content of the base oil feedstock. Nitrogen content is less than 2000 ppm, or less than 1500 ppm, or less than 1000 ppm, or less than 500 ppm, or less than 200 ppm, or less than 100 ppm; Sulfur content less than 6000 ppm, or less than 4000 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, 100-6000 ppm, 100-4000 ppm, 100-2000 ppm, 100-1000 ppm, 100-500 ppm, or 100-200 ppm; and / or The 1050+℉ content is in the range of 5-40% by weight or 8-40% by weight, or optionally, greater than the 1050+℉ content of the base oil feedstock.

4. The process according to any one of claims 1-3, wherein the base oil feedstock is: (a) comprising 10-60 wt% atmospheric residue feedstock and 40-90 wt% base oil feedstock, or 10-40 wt% atmospheric residue feedstock and 60-90 wt% base oil feedstock, or 10-30 wt% atmospheric residue feedstock and 70-90 wt% base oil feedstock, or 30-60 wt% atmospheric residue feedstock and 40-70 wt% base oil feedstock, or 40-60 wt% atmospheric residue feedstock and 40-60 wt% base oil feedstock, and / or (b) The base oil feed stream contains no additives, or the base oil feed stream does not contain vacuum residue feed stream, or the base oil feed stream does not contain deasphalted oil, or the base oil feed stream contains only atmospheric residue feed stream and base oil feed stream.

5. The process according to any one of claims 1-4, wherein the process does not include recycling the liquid feedstock as part of the base oil feed stream or as one or both of the atmospheric residue feedstock and the base oil feedstock.

6. The process according to any one of claims 1-5, wherein the base oil feedstock comprises vacuum gas oil or vacuum gas oil, or is substantially composed of vacuum gas oil, or is composed of vacuum gas oil, optionally, wherein the vacuum gas oil is heavy vacuum gas oil obtained from vacuum gas oil, wherein the vacuum gas oil is cut into light fractions and heavy fractions, wherein the cutting point temperature range of the heavy fraction is about 950-1050℉.

7. The process according to any one of claims 1-6, wherein the dewaxing product and / or the hydrorefining dewaxing product are obtained as light base oil products and heavy base oil products, optionally wherein the nominal viscosity of the light base oil product at 100°C is in the range of 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 10-14 cSt or 11-13 cSt.

8. The process of claim 7, wherein (a) Compared to the same process in which the atmospheric residue feedstock is not included in the base oil feedstream, the yield of the heavy base oil product relative to the light base oil product increases by at least about 2 L / v or at least about 5 L / v, and / or (b) Compared with the same process that does not include the atmospheric residue feedstock in the base oil feed stream, the overall waxy base oil yield increases by at least about 2 L / v or at least about 5 L / v.

9. The process according to any one of claims 1-7, wherein the dewaxed product is further separated into a lighter product having a nominal viscosity of at least 6 cSt at 100°C, or a heavier product having a nominal viscosity of at least 12 cSt at 100°C, or a combination of both.

10. A method for modifying a base oil process, wherein the base oil process includes subjecting a base oil feed stream to hydrocracking and dewaxing steps to form a dewaxed product comprising light and heavy products; the method includes, Atmospheric residue feedstock and base oil feedstock are combined to form the base oil feed stream; as well as The base oil feed stream, which includes the atmospheric residue feedstock, is subjected to the hydrocracking and dewaxing steps of the base oil process. The modified base oil process includes: Atmospheric residue feedstock and base oil feedstock are combined to form a base oil feed stream; The base oil feed stream is contacted with a hydrocracking catalyst under hydrocracking conditions to form hydrocracking products; The hydrocracking products are separated into at least gaseous and liquid fractions; The liquid fraction is contacted with a dewaxing catalyst under hydroisomerization conditions to produce a dewaxing product; and Optionally, the dewaxed product is contacted with a hydrorefining catalyst under hydrorefining conditions to produce a hydrorefined dewaxed product. The atmospheric residue feedstock described herein meets one or more of the following conditions: API severity is in the range of 20-45; VI is in the range of 90-180; The viscosity at 100℃ is in the range of 3-20 cSt; The viscosity at 70℃ is in the range of 5-20 cSt; The asphalt content of hot C7 is in the range of 0.02-0.15% by weight; The wax content is in the range of 5-40% by weight; Nitrogen content less than 1500 ppm; Sulfur content less than 6000 ppm; and / or The content of 1050+℉ is in the range of 5-40% by weight. The base oil feedstock described herein meets one or more of the following conditions: API severity is in the range of 15-40; VI is in the range of 30-90; The viscosity at 100℃ is in the range of 3-30 cSt; The viscosity at 70℃ is in the range of 5-25 cSt; The asphalt content of hot C7 is in the range of 0.01-0.3% by weight; The wax content is in the range of 5-40% by weight; Nitrogen content less than 2500 ppm; Sulfur content less than 8000 ppm; and / or Content of 1050+℉ is 5-50% by weight.

11. A process for manufacturing base oils, comprising: Under hydrocracking conditions, a base oil feedstock with a viscosity index of about 100 or higher is contacted with a hydrocracking catalyst to form hydrocracking products, wherein the base oil feedstock includes vacuum gas oil with a front-end cut point of about 700℉ or higher and a rear-end cut point of about 900℉ or lower. The hydrocracking products are separated into gaseous and liquid fractions; The liquid fraction is contacted with a dewaxing catalyst under hydroisomerization conditions to produce a dewaxing product; as well as Optionally, the dewaxed product is contacted with a hydrorefining catalyst under hydrorefining conditions to produce a hydrorefined dewaxed product; Wherein, the viscosity index of the dewaxed product and / or the hydrorefined dewaxed product is 120 or higher after dewaxing.

12. The process of claim 11, wherein: (a) The viscosity index of the dewaxed product and / or the hydrotreated dewaxed product is 130 or higher after dewaxing, or 135 or higher after dewaxing, or 140 or higher after dewaxing, or (b) The dewaxing product and / or the hydrorefining dewaxing product comprises Group III or Group III+ base oil products, or (c) The viscosity index of the hydrocracking product is at least about 135 or 140 or 145 or 150.

13. The process of claim 11 or 12, wherein the yield of waxy product with a front-end cut point of about 700℉ or higher and a rear-end cut point of about 900℉ or lower at a viscosity of 4cSt at 100°C is at least about 3L higher by volume than that of the same process excluding the use of vacuum gas oil with a front-end cut point of about 700℉ or higher and a rear-end cut point of about 900℉ or lower as the base oil feedstock.

14. A process for producing base oils from base oil feedstocks or their fractions, the process comprising: Atmospheric residue fractions are provided from base oil feedstocks or their fractions; The base oil feedstock or its fraction and / or the atmospheric residue fraction of the base oil are separated into vacuum gas oil cut-point fractions with a front cut-point of about 700℉ or higher and a rear cut-point of about 900℉ or lower, to form medium vacuum gas oil MVGO fraction and heavy vacuum gas oil HHVGO fraction. The HHVGO fraction is used as the atmospheric residue feedstock in the process described in claim 1; and / or The MVGO fraction is used as the base oil feedstock in the process described in claim 10.

15. The process of claim 14, wherein the base oil feedstock comprises tight oil or a fraction thereof, optionally wherein the vacuum gas oil cut-point fraction is derived from the atmospheric residue fraction of the tight oil.

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