Process for producing an intermediate residue

Abstract

The present invention relates to a process for producing middle distillates from a feedstock comprising a residual hydrocarbon feedstock and a hydrogen-deficient feedstock. The process comprises: (a) a step of dewaxing the residual hydrocarbon feedstock to obtain a dewaxed product having at least 50% by weight of a boiling point above 550 °C and an asphaltene product; (b) a step of combining the dewaxed product with the hydrogen-deficient feedstock to produce a mixed dewaxed product, wherein the hydrogen-deficient feedstock has a hydrogen (H) content of at least 6% by weight to a maximum of 11.3% by weight; (c) a step of hydrodemetallizing at least a part of the mixed dewaxed product obtained from step (b) to produce a hydrodemetallized product; (d) a step of hydrotreating at least a part of the hydrodemetallized product obtained from step (c) to produce a hydrotreated product; (e) a step of hydrocracking at least a part of the hydrotreated product obtained from step (d) to produce a hydrocracked product; and (f) a step of subjecting at least a part of the hydrocracked product obtained from step (e) to a separation treatment to produce at least a middle distillate fraction.

Description

Technical Field

[0001] The present invention relates to a process for producing middle distillates from residual hydrocarbon-based feeds and hydrogen-deficient feeds.

Background Art

[0002] In view of the increasing environmental awareness that seeks to reduce the carbon footprint of various processes, many research and developments are directed not only to increasing the yield of middle distillates but also to the treatment of low-hydrogen-containing feeds, which may increase the production of ultra-low-sulfur middle distillates such as ultra-low-sulfur diesel fuel that may include a portion of renewable origin.

[0003] First, it is known to produce ultra-low-sulfur diesel fuel by hydrodesulfurizing a hydrocarbon distillate stream boiling in the boiling range of gas oil and then dewaxing the desulfurized distillate stream with a catalyst. Especially in winter, a catalytic dewaxing step may be required to remove waxy molecules from the distillate stream to lower the cloud point and pour point of the gas oil. To saturate aromatic compounds, a hydrofinishing may be carried out on the desulfurized and dewaxed gas oil. In this way, the cetane index or cetane number of the gas oil product can be further increased. Then, the gas oil obtained by desulfurizing, dewaxing, and optionally hydrofinishing is used as diesel fuel or a component of diesel fuel.

Summary of the Invention

[0004] The object of the present invention is to provide a process for producing ultra-low-sulfur middle distillates in high yield and incorporating hydrogen-deficient feeds.

[0005] This object is achieved when using a specific multi-stage process. Accordingly, the present invention is a process for producing middle distillates from a feedstock comprising a residual hydrocarbon-based feedstock and a hydrogen-deficient feedstock, (a) a step of decoking a residual hydrocarbon-based feedstock to obtain a decoked product having at least 50% by weight of a boiling point above 550°C and an asphaltene-based product; (b) A step of combining the stripped product with a hydrogen-deficient feedstock to produce a mixed stripped product, wherein the hydrogen-deficient feedstock has a hydrogen (H) content of at least 6 wt% to a maximum of 11.3 wt%. (c) A step of hydrodemetallizing at least a part of the mixed stripped product obtained from step (b) to produce a hydrodemetallized product. (d) A step of hydrotreating at least a part of the hydrodemetallized product obtained from step (c) to produce a hydrotreated product. (e) A step of hydrocracking at least a part of the hydrotreated product obtained from step (d) to produce a hydrocracked product. (f) A step of subjecting at least a part of the hydrocracked product obtained from step (e) to a separation treatment to produce at least an intermediate distillate fraction. Relates to a process comprising.

[0006] According to the present invention, a high-yield intermediate distillate containing less than 10 ppm by weight of sulfur can be advantageously produced from a residue hydrocarbon-based feedstock and a hydrogen-deficient feedstock.

Brief Description of the Drawings

[0007]

Figure 1

Figure 2

Figure 3

Figure 4

Modes for Carrying Out the Invention

[0008] The residual hydrocarbon-based feedstock used according to the present invention can be a residual hydrocarbon oil, such as that obtained by distillation of crude oil under atmospheric pressure or reduced pressure. Preferably, at least 55% by weight, preferably at least 75% by weight, more preferably at least 85% by weight, even more preferably at least 90% by weight of the residual hydrocarbon-based feedstock has a boiling point above 550 °C. However, atmospheric residue or vacuum residue contains a considerable amount of high molecular weight non-distillable compounds such as asphaltenes. Therefore, it is considered desirable to remove asphaltenes from the residual hydrocarbon oil feedstock before subjecting the residual hydrocarbon oil to a subsequent upgrading process.

[0009] In step (a), the residual hydrocarbon-based feedstock is dewaxed to obtain a dewaxed product in which at least 50% by weight, preferably at least 70% by weight, more preferably at least 80% by weight, even more preferably at least 85% by weight has a boiling point above 550 °C, and an asphalt-based product.

[0010] The dewaxing in step (a) can be carried out by any conventional method. A well-known preferred dewaxing method is solvent dewaxing. According to the present invention, the dewaxing in step (a) is preferably carried out by a solvent dewaxing treatment.

[0011] In solvent dewaxing, a hydrocarbon feedstock is treated countercurrently with an extraction medium which is a light hydrocarbon solvent, usually containing paraffinic compounds. Well-known paraffinic compounds include C3 - 8 paraffinic hydrocarbons, such as propane, n-butane, isobutane, n-pentane, isopentane, hexane or a mixture of two or more of these. For the purposes of the present invention, it is preferred to use C3 - C5 paraffinic hydrocarbons, most preferably butane, pentane or a mixture thereof as the extraction solvent. Generally, the extraction depth increases as the number of carbon atoms in the extraction solvent increases. In this connection, it should be noted that the greater the extraction depth, the greater the amount of hydrocarbon extracted from the residual hydrocarbon feedstock, and the asphaltene-based product will be small and highly viscous, whereby the asphaltenes in the asphaltene-based product obtained in step (a) will be heavy.

[0012] In the solvent dewaxing process, a rotating disk contactor or a plate column can be used, with the residual hydrocarbon feedstock entering from the top and the extraction solvent entering from the bottom. The light hydrocarbons present in the residual hydrocarbon feedstock dissolve in the extraction solvent and are taken out as the dewaxed product at the top of the apparatus. The asphaltenes, which are insoluble in the extraction solvent, are recovered at the bottom of the apparatus in the form of an asphaltene-based product. The conditions for carrying out the dewaxing are known in the art. Preferably, the dewaxing is carried out at a ratio of total extraction solvent to residual hydrocarbon oil of 1.5 - 8 wt / wt, a pressure of 1 - 60 bara, and a temperature of 40 - 200 °C.

[0013] The dewaxing process generally accumulates a significant amount of metal contaminants present in the feedstock as high molecular weight complexes in the asphaltene-based product rather than in the dewaxed product. Nevertheless, the metal content of the dewaxed product is such that it needs to be subjected to a hydrodemetallation step before it can be subjected to a further hydrotreating upgrading process.

[0014] In step (b), at least a portion of the decoked product is combined with a hydrogen-deficient feedstock to produce a mixed decoked product. Preferably, in step (b), the entire decoked product obtained in step (a) is combined with the hydrogen-deficient feedstock. By adding the hydrogen-deficient feedstock, low-value products obtained from other processes are utilized, and by increasing the amount of the middle distillate product, the carbon footprint of the process is reduced.

[0015] In some embodiments, the mixed decoked product should have a hydrogen content of less than at least 0.1 wt% of the decoked product by the addition of the hydrogen-deficient feedstock. In other embodiments, the hydrogen content of the mixed decoked product should be at most 2 wt% lower than that of the decoked product by the addition of the hydrogen-deficient feedstock. In some embodiments, the amount of the hydrogen-deficient feedstock occupies up to about 50 wt%, or up to about 40 wt%, or up to about 30 wt% of the mixed decoked product.

[0016] The decoked product obtained from step (a) is a heavy decoked product. This means that at least 50 wt%, preferably at least 70 wt%, more preferably at least 80 wt%, and even more preferably at least 85 wt% of the decoked product treated in step (b) has a boiling point above 550 °C.

[0017] The hydrogen-deficient feedstock has a hydrogen (H) content of at least 6 wt% to a maximum of 11.3 wt% and a true-boiling point chromatography (TBP-GLC) distillation temperature of more than 280 °C for 10 wt%. Examples of such hydrogen-deficient feedstocks can be slurry oil from a fluid catalytic cracking unit, tall oil pitch obtained from the distillation of crude tall oil, and residues from an ethylene cracking unit derived from either fossil fuels and / or waste plastic feedstocks. In some embodiments, the waste plastic feedstock can be treated by pyrolysis and / or hydrogenation before being fed to the ethylene cracking unit.

[0018] Slurry oil is the bottom product from the main distillation column of a Fluid Catalytic Cracker (FCC) and is a blending component for marine fuels. Slurry oil has a relative viscosity of 5 - 25 cSt (5 - 25 mm2 / s) at 100 °C and a total aromatic content of 35 - 65 wt%. Hydrogen-deficient slurry oil has a hydrogen content of about 8.2 - about 9.2 wt%. The slurry oil has a TBP-GLC distillation temperature at 10 wt% of about 360 °C (680 °F).

[0019] Tall Oil Pitch (TOP) is a by-product of the distillation of Crude Tall Oil (CTO). One current use of TOP is as a bioheating fuel or as a replacement for non-renewable fossil energy. CTO is a by-product of the pulp and paper industry that processes wood pulp from pine trees. Hydrogen-deficient TOP has a hydrogen content of about 10.7 - 11.1 wt%, and TOP has a TBP-GLC distillation temperature at 10 wt% of at least 350 °C (662 °F). TOP has a viscosity of 60 - 100 cSt (60 - 100 mm2 / s) at 70 °C. The use of TOP converts renewable pitch into valuable products including automotive fuels. TOP is considered a renewable feedstock component and may provide carbon credits.

[0020] In step (c), at least a part of the mixed decanted product obtained in step (b) is hydrodemetallated to obtain a hydrodemetallated product. Preferably, in step (c), the entire mixed decanted product obtained in step (b) is hydrodemetallated.

[0021] The hydrodemetallization of the mixed coked product in step (c) can be achieved by any well-known hydrodemetallization process, where the mixed coked product to be hydrodemetallized passes through one or more vertically arranged reactors containing a fixed bed or a moving bed of hydrodemetallization catalyst particles under high temperature and high pressure in the presence of hydrogen, either upward, downward, or radially. In one embodiment, the hydrogen for the hydrodemetallization reaction can be produced, for example, although not particularly limited, by water electrolysis. The process of water electrolysis can be powered by renewable energy (such as solar power generation, wind power generation, or hydroelectric power generation) that produces green hydrogen, nuclear energy, or non-renewable electricity from other sources (gray hydrogen).

[0022] Hydrodemetallization can be carried out in a bunker flow reactor, a fixed bed reactor, a fixed bed swing reactor, or a moving bed reactor. Preferably, the hydrodemetallization in step (c) is carried out at least in part in a bunker flow reactor or a moving bed reactor.

[0023] In step (c), a hydrodemetallization catalyst is used. Suitable hydrodemetallization catalysts for use according to the present invention are those composed of an oxide support such as alumina, silica, or silica-alumina, on which one or more Group VIB metals or Group VIII metals, or metal compounds can be deposited. Such hydrodemetallization catalysts are commercially available from a number of catalyst suppliers. Particularly suitable hydrodemetallization catalysts are those having, as an activator, one of the combinations of nickel / molybdenum (NiMo) or cobalt / molybdenum (CoMo), optionally strengthened with phosphorus (P), on an alumina (Al2O3) support. Specific examples of particularly suitable catalysts include CoMo / Al2O3 catalyst, CoMoP / Al2O3 catalyst, NiMo / Al2O3 catalyst, and NiMoP / Al2O3 catalyst.

[0024] The hydrodemetallization in step (c) can preferably be carried out at a hydrogen partial pressure of 20 to 300 bara, preferably 50 to 210 bara, a temperature of 300 to 460 °C, preferably 310 to 435 °C, and a space velocity of 0.1 / hour to 10 / hour, preferably 0.2 / hour to 7 / hour. In some embodiments, by using a pure and heavy decanted product in step (c), a significant amount of metal will be deposited on the hydrodemetallization catalyst used in step (c). As a result, the hydrodemetallization catalyst(s) will deteriorate / deactivate extremely rapidly, and compared with known processes that feed a diluted, lighter decanted product with a lower metal content to the hydrodemetallization step, it will be necessary to replace the hydrodemetallization catalyst(s) much more regularly and rapidly. Therefore, the hydrodemetallization reactor is preferably a bunker flow reactor, a fixed bed swing reactor or a moving bed reactor. The hydrodemetallization catalyst(s) is / are replaced regularly, for example, every three weeks or two months, while in conventional processes, the hydrodemetallization catalyst (such as the hydrotreating catalyst and the hydrocracking catalyst used in steps (d) and (e) of this process) may not be replaced within one year.

[0025] In step (d), at least a part of the hydrodemetallized product obtained in step (c) is hydrotreated to obtain a hydrotreated product. Preferably, in step (d), the entire hydrodemetallized product obtained in step (c) is hydrotreated.

[0026] The hydrotreating of the hydrodemetallization product in step (d) can be achieved by any well-known hydrotreating process, where the hydrodemetallization product to be hydrotreated passes through one or more vertically arranged reactors, including a fixed bed or a moving bed of hydrotreating catalyst particles, under high temperature and high pressure in the presence of hydrogen, either upward, downward, or radially. In one embodiment, hydrogen for the hydrotreating reaction can be generated, for example, although not particularly limited, by water electrolysis. The process of water electrolysis can be powered by renewable energy (such as solar power generation, wind power generation, or hydropower generation) that produces green hydrogen, nuclear energy, or non-renewable electricity from other sources (gray hydrogen). The hydrotreating can be carried out in a bunker flow reactor, a fixed bed reactor, a fixed bed swing reactor, or a moving bed reactor. Preferably, the hydrotreating in step (d) is carried out in two reaction zones, whereby the hydrodemetallization product is first passed through a first reaction zone where the hydrodemetallization product is partially hydrotreated, and then the partially hydrotreated effluent thus obtained is subjected to further hydrotreating in a second reaction zone. The first reaction zone and the second reaction zone can be arranged in a stacked type, or the two reaction zones can be arranged in separate reactors. Preferably, the first reaction zone and the second reaction zone are arranged in a first reactor and a second reactor, respectively. The first reactor can be a bunker flow reactor, and the second reactor can be a fixed bed reactor.

[0027] The hydrogenation catalyst used in step (d) may preferably be a desulfurization catalyst. The desulfurization catalyst can be any hydrodesulfurization catalyst known in the art. Suitable hydrodesulfurization catalysts include a porous catalyst support, usually on alumina or amorphous silica-alumina, and contain compounds of Group VIII metals of the periodic table and Group VIB metals of the periodic table as hydrogenation components. Well-known examples of suitable combinations of hydrogenation compounds include cobalt-molybdenum, nickel-molybdenum, nickel-tungsten, and nickel-cobalt-molybdenum. A hydrodesulfurization catalyst containing compounds of nickel and / or cobalt and molybdenum as hydrogenation compounds is preferred. The hydrodesulfurization catalyst may further contain a cracking component such as, for example, Y zeolite. However, it is preferred that substantial hydrocracking does not occur in the hydrogenation treatment in step (d). Therefore, it is preferred that the catalyst does not substantially contain a cracking component. A catalyst containing nickel and / or cobalt and molybdenum supported on alumina without a zeolite-based cracking compound is particularly preferred.

[0028] The hydrogenation treatment conditions in step (d), namely, temperature, pressure, hydrogen supply rate, and weight hourly velocity of the raw material, are typical hydrogenation treatment conditions. Preferably, the temperature used for the hydrogenation treatment in step (c) is within the range of 280 to 430 °C, more preferably within the range of 320 to 420 °C, and most preferably within the range of 330 to 410 °C.

[0029] The suitable hydrogenation treatment pressure is within the range of 10 to 300 bara. Preferably, the hydrogenation treatment pressure is within the range of 30 to 250 bara, and more preferably within the range of 80 to 220 bara.

[0030] In step (e), at least a part of the hydrogenation treatment product obtained in step (d) is hydrocracked to obtain a hydrocracked product. Preferably, in step (e), the entire hydrogenation treatment product obtained in step (d) is hydrocracked.

[0031] The hydrocracking in step (e) of the process according to the present invention can be carried out by any method known in the art, provided that at least one of the catalysts used in the hydrocracking zone is acidic. Preferably, the hydrocracking is carried out under high temperature and high pressure in the presence of hydrogen and a suitable hydrocracking catalyst. In one embodiment, hydrogen for the hydrocracking reaction can be produced, for example, by water electrolysis, without particular limitation. The process of water electrolysis can be supplied with power by renewable energy (such as solar power generation, wind power generation or hydropower generation) that generates green hydrogen, nuclear energy, or non-renewable power from other sources (gray hydrogen). Suitable hydrocracking catalysts consist of one or more metals from nickel, tungsten, cobalt and molybdenum in elemental form, oxide form or sulfide form on a suitable support such as alumina, silica, silica-alumina or zeolite. There are many commercially available hydrocracking catalysts that can be preferably used in the process of the present invention. At least one of the catalysts used in the hydrocracking zone must be acidic, that is, it must contain a silica-alumina component and / or a zeolite component.

[0032] The hydrocracking in step (e) can be carried out in a one-stage or multi-stage operation mode. In the case of a one-stage operation mode, a catalyst obtained by laminating a hydrodenitrogenation / first-stage hydrocracking catalyst on a conversion catalyst can be preferably used. Particularly preferred hydrodenitrogenation / first-stage hydrocracking catalysts are NiMo / Al2O3 and CoMo / Al2O3 optionally strengthened with phosphorus and / or fluorine. Preferred conversion catalysts are mainly NiW / zeolite or NiW / zeolite / silica-alumina. Suitable hydrocracking conditions in step (e) are that the operating pressure is 80-250 bara, preferably 90-220 bara, and the temperature is 300-460 °C, preferably 350-430 °C.

[0033] Although not bound by theory, it has surprisingly been found that by introducing a hydrogen-deficient feedstock as part of the mixed effluent product, only the activity of the catalyst in the hydrodemetallization reactor increases. For example, in a simulation where slurry oil (SLO) is included in deasphalted oil (DAO) to form a mixed DAO feedstock, the average hydrogen content of the DAO feedstock decreased by 0.3 wt%, and the exothermicity on the hydrodemetallization catalyst increased by 20%, but the exothermicity on the subsequent hydrotreating and hydrocracking catalysts remained nearly constant. This increase in the activity of the hydrodemetallization catalyst allows the inlet temperature of the (first) hydrodemetallization reactor to be lowered, reducing the load on the reactor feed heating furnace to the hydrodemetallization reactor, which can then be utilized to increase the cycle length of the unit.

[0034] In step (f), at least a portion of the hydrocracked product obtained in step (e) is separated to obtain at least an intermediate distillate fraction. Preferably, in step (f), the entire hydrocracked product obtained in step (e) is subjected to the separation process.

[0035] The separation process of step (f) can preferably be a fractional distillation process carried out at a temperature in the range of 50 to 400 °C, preferably in the range of 70 to 370 °C, and a pressure in the range of 0.03 to 15 bara, preferably in the range of 0.05 to 10 bara.

[0036] From step (f), a fuel gas fraction can also be obtained, preferably containing C1 - C2 products. In other embodiments, the fuel gas fraction can contain C1 - C4 products. In some embodiments, when a renewable hydrogen-deficient feedstock is used in step (b), at least a portion of the fuel gas fraction has a renewable origin. Thus, when fuel gas having a renewable origin is used for hydrogen production, a portion of the hydrogen produced can be considered to have a renewable origin.

[0037] In addition to the middle distillate fraction obtained in step (f), a heavy residue fraction can be obtained. Preferably, at least 80% by weight of the heavy residue fraction similarly obtained in the separation process in step (f) has a boiling point above 370°C. Preferably, at least 90% by weight of the heavy residue fraction similarly obtained in the separation process in step (f) has a boiling point above 370°C.

[0038] At least a part of the heavy residue fraction similarly obtained in step (f) can be recycled to step (a). In this way, an improvement in the yield of the middle distillate can be achieved.

[0039] Alternatively, the heavy fraction can be suitably used as a feedstock for a fluidised bed catalytic cracking (FCC) unit or as a feedstock for lubricating oil production. Naturally, it is also possible to combine these options.

[0040] To achieve an optimal yield of the middle distillate, it is preferred that at least a part of the heavy fraction obtained in step (f) is subjected to hydrocracking again to improve the yield of the middle distillate. Therefore, in a preferred embodiment, at least a part of the heavy residue fraction similarly obtained in step (f) is recycled to step (e).

[0041] In another preferred embodiment of the present invention, at least a part of the heavy residue fraction similarly obtained in step (f) is recycled to step (a), and at least a part of the heavy residue fraction similarly obtained in step (f) is recycled to step (e). In this way, the yield of the middle distillate is further improved.

[0042] In yet another preferred embodiment, at least a part of the heavy residue fraction similarly obtained in step (f) is subjected to a further hydrocracking step (g), and at least a part of the hydrocracked product obtained in such step (g) is recycled to step (f). This embodiment also ensures that an optimal yield of the middle distillate is established.

[0043] Preferably, at least a part of the heavy residue fraction obtained similarly in step (f) is also recycled to step (a) to further improve the yield of the middle distillate.

[0044] Preferably, the hydrocracking in step (e) and / or step (g) is carried out in two or more reaction zones. Preferably, the two or more reaction zones are arranged in a stacked type.

[0045] Preferably, at least a part of the asphaltene-based product obtained in step (a) is subjected to a gasification step (h) to obtain hydrogen and carbon monoxide. In some embodiments, when a renewable hydrogen-deficient feedstock is used in step (b) and at least a part of the heavy residue fraction obtained similarly in step (f) is recycled to step (a), the asphaltene-based product obtained in step (a) has a part of renewable origin.

[0046] The asphaltene-based product obtained in step (a) can be utilized in several ways. For example, it can be burned for the co-generation of power and steam. Alternatively, it can be partially burned for the production of clean fuel gas, the co-generation of power and steam, hydrogen production or hydrocarbon synthesis. In another embodiment, when the asphaltene has a part of renewable origin, the hydrogen produced therefrom can be considered to be partially of green origin. As yet another option, there is the utilization for bitumen, emulsion fuel or solid fuel by pelletization.

[0047] Preferably, such a gasification step (h) is a partial combustion step.

[0048] In a preferred embodiment, at least a part of the hydrogen obtained in step (h) is recycled to at least one of step (c), step (d), step (e) and step (g).

[0049] The middle distillate fraction obtained in step (f) includes a middle distillate containing less than 10 ppm by weight of sulfur. Preferably, the middle distillate contains less than 8 ppm by weight of sulfur, more preferably less than 6 ppm by weight of sulfur, and most preferably less than 5 ppm by weight of sulfur.

[0050] Figure 1 shows the process according to the present invention, Figure 2 shows another embodiment of the present invention, and Figure 3 shows a further embodiment of the process according to the present invention.

[0051] In Figure 1, an atmospheric hydrocarbon oil residue or a vacuum hydrocarbon oil residue is sent via line 1 to the decoking unit 2, where a decoked product and an asphaltene-based product are obtained. A hydrogen-deficient feedstock is supplied via line 20 and combined with at least a part of the decoked product in line 3 to form a mixed decoked product. At least a part of the mixed decoked product is sent to the hydrodemetallization unit 5, and the asphaltene-based product is taken out from the decoking unit 2 via line 4. At least a part of the hydrodemetallized product obtained in the hydrodemetallization unit 5 is sent via line 6 to the hydrotreating unit 7. At least a part of the hydrotreated product obtained in the hydrotreating unit 7 is then sent via line 8 to the hydrocracking unit 9. At least a part of the hydrocracked product obtained in the hydrocracking unit 9 is sent via line 10 to the fractionation unit 11, from which at least a middle distillate fraction is recovered via line 12.

[0052] Figure 2 is an extension of Figure 1. In the fractionation unit 11, a heavy residue fraction is also obtained, which is taken out from the fractionation unit 11 via line 13, and at least a part of the heavy residue fraction is recycled to the decoking unit 2.

[0053] FIG. 3 is an extension of FIG. 2. In the fractionation unit 11, a heavy residue fraction is also obtained, which is taken out from the fractionation unit 11 via line 13. At least a part of the heavy residue fraction is recycled to the hydrocracking unit 9 via line 14, and / or at least a part of the heavy residue fraction is recycled to the hydrodemetallization unit 5 via line 15, and / or at least a part of the heavy residue fraction is recycled to the decoking unit 2 via line 16.

[0054] FIG. 4 is an extension of FIG. 1. In the fractionation unit 11, a heavy residue fraction is also obtained, which is taken out from the fractionation unit 11 via line 13. At least a part of the heavy residue fraction is sent to the hydrocracking unit 17 via line 13, and at least a distillate fraction is recovered therefrom via line 21. At least a part of the hydrocracked product obtained in the hydrocracking unit 14 is recycled to the fractionation unit 11 via lines 18 and 19, and at least a part of the heavy residue fraction obtained in the fractionation unit 11 is recycled to the decoking unit 2 via lines 18 and 20.

[0055] Although several embodiments of the present disclosure have been described in detail above, those skilled in the art will readily understand that many modifications can be made without substantially departing from the teachings of the present disclosure. Accordingly, such modifications are intended to be included within the scope of the present disclosure as defined in the claims.

Claims

1. A process for producing an intermediate distillate from raw materials including residual hydrocarbon raw materials and hydrogen-deficient raw materials, (a) A step of de-cleaving the residual hydrocarbon raw material to obtain a de-cleaved product having a boiling point of more than 550°C in at least 50% by weight, and an asphalt-based product, (b) A step of producing a mixed de-de (c) A step of hydrogenating and demetallizing at least a portion of the mixed demetallized product obtained from step (b) to produce a hydrogenated demetallized product, (d) A step of hydrogenating at least a portion of the hydrogenation demetallation product obtained from step (c) to produce a hydrogenated product, (e) A step of hydrogenocracking at least a portion of the hydrogenation treatment product obtained from step (d) to produce a hydrogenocracked product, (f) A step of subjecting at least a portion of the hydrogenocrack product obtained from step (e) to a separation process to produce at least an intermediate distillate fraction, A process that includes this.

2. The process according to claim 1, wherein the amount of hydrogen-deficient raw material accounts for up to approximately 50% by weight of the mixed de-abrasive product.

3. The process according to claim 1, wherein the mixed de-abrasive product has a hydrogen content of less than 0.1% by weight of the de-abrasive product by the addition of the hydrogen-deficient raw material.

4. The process according to any one of claims 1 to 3, wherein at least a portion of the hydrogen-deficient raw materials includes a portion of renewable sources.

5. The process according to any one of claims 1 to 3, wherein the hydrogen-deficient raw material includes slurry oil from a fluid catalytic cracking unit.

6. The process according to claim 4, wherein the hydrogen-deficient raw material includes tall oil pitch from the distillation of crude tall oil.

7. The process according to claim 1 or 2, wherein the intermediate distillate fraction in the generated step (f) contains less than 10 ppm by weight of sulfur.

8. The process according to claim 1 or 2, wherein the separation treatment in step (f) generates a heavy residue fraction having a boiling point of over 370°C, with 80% by weight being the result of the separation treatment in step (f).

9. The process according to claim 4, wherein the separation process in step (f) also produces a fuel gas fraction having a portion of its renewable origin.

10. The process according to claim 4, wherein at least a portion of the asphalt-based product obtained in step (a) is subjected to a gasification step (h) to obtain hydrogen and carbon monoxide having a portion of a renewable origin.

Images