Process for improving base oil yield

Abstract

To provide an improved base oil preparation process for utilizing different raw materials and improving the yield of useful base oil products.SOLUTION: Wherein the process comprises contacting a base oil feed having a viscosity index of about 100 or greater with a hydrocracking catalyst under hydrocracking conditions to form a hydrocrackate, wherein the front end cut temperature is about 700 °F. or greater; Wherein the base stock comprises a vacuum gas oil having a back end cut temperature of about 900 °F or less, separating the hydrocracked product into a gaseous fraction and a liquid fraction, contacting the liquid fraction with a dewaxing catalyst under hydroisomerization conditions to obtain a dewaxed product, and optionally contacting the dewaxed product with a hydrofinishing catalyst under hydrofinishing conditions to obtain a hydrofinished dewaxed product, wherein after dewaxing, the dewaxed product and / or the hydrofinished dewaxed product has a viscosity index of 120 or more.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of priority to U.S. Provisional Patent Application No. 62 / 885,359, filed August 12, 2019, the disclosure of which is incorporated herein in its entirety.

[0002] The present invention relates to a process for improving base oil yield by combining an atmospheric resid feed with a base oil feed to form an integrated feedstream from which a base oil product is formed via hydroprocessing. [Background technology]

[0003] High-quality lubricating base oils (e.g., those with a viscosity index (VI) of 120 or greater (Group II and Group III)) can generally be produced from high-boiling vacuum distillate fractions (e.g., vacuum gas oil (VGO)) by hydrocracking to increase the VI, followed by catalytic dewaxing to lower the pour point and cloud point, and hydrofinishing to saturate aromatics and improve stability. Hydrocracking breaks down high-boiling molecules to yield molecules with reduced boiling points, which not only increase the VI but also reduce the viscosity. To produce high-VI, high-viscosity grade base oils in high yields, the feed to the hydrocracker must contain a certain amount of high-boiling molecules. Typically, practical limitations on temperature and pressure limit the ability of VGO to recover very high-boiling molecules from atmospheric resid (AR) in the vacuum column. One possible means of supplying higher boiling point molecules to the hydrocracker is to feed AR directly, but this is usually not feasible or viable because AR typically contains materials that are extremely detrimental to the hydrocracker catalyst (e.g., nickel, vanadium, microcarbon residue (MCR), and asphaltenes). These materials unacceptably shorten the life of the hydrocracker catalyst, making the use of such feedstocks impractical.

[0004] One approach to using difficult whole crudes and other intermediate feedstocks in preparing base oils is to first process such feedstocks (such as AR or vacuum residue (VR)) in a solvent deasphalting (SDA) unit. Such processing typically requires separating most of the undesirable materials while producing a deasphalted oil (DAO) of acceptable quality for use as feedstock to a hydrocracker. However, the significant capital requirements and high operating costs of such SDA units and the overall process approach make their use undesirable. Other approaches have been implemented to minimize or eliminate the need for the solvent deasphalting step, but these approaches have not provided any clear benefits in terms of cost or other process improvements.

[0005] The production of Group III base oils and finished lubricants has typically required the use of expensive and limited-supply viscosity index improvers (such as polyalphaolefins) or other expensive processing techniques (such as those using gas-to-liquid (GTL) feedstocks or, for example, by multiple hydrocracking processes of mineral oils). Producing Group III base oils generally requires high-quality feedstock(s) and high conversion processing to meet VI targets, even at the expense of product yield. However, despite continued efforts by the industry, the development and commercialization of relatively inexpensive and suitable feedstocks and simple processes for preparing such products has not yet been achieved.

[0006] Although progress has been made in producing base oils from different and difficult feedstocks, there is a continuing need for improved processes to utilize different feedstocks and increase the yield of useful base oil products. Summary of the Invention

[0007] The present invention is directed to a process for preparing base oil products, specifically light and heavy grade base oil products, via hydroprocessing of base oil feedstreams. One goal of the present invention, although not necessarily limiting, is to improve the base oil yield of the heavy grade base oil product while producing Group II base oil and / or Group III / III+ base oil.

[0008] In general, a first process according to the present invention includes preparing a base oil by combining an atmospheric resid feed and a base oil feed to form a base oil feedstream, contacting the base oil feedstream with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracked product, separating the hydrocracked product into a gaseous fraction and a liquid fraction, contacting the liquid fraction with a dewaxing catalyst under hydroisomerization conditions to obtain a dewaxed product, and optionally contacting the dewaxed product with a hydrofinishing catalyst under hydrofinishing conditions to obtain a hydrofinished dewaxed product.

[0009] The present invention also relates to a method for modifying a base oil process by adding an atmospheric resid feed to a base oil feed in a conventional base oil process that includes subjecting the base oil feedstream to hydrocracking and dewaxing steps to form a dewaxed product comprising light and heavy products. The modified base oil process thus includes combining an atmospheric resid feed and a base oil feed to form a base oil feedstream, contacting the base oil feedstream with a hydrocracking catalyst under hydrocracking conditions to form hydrocracked products, separating the hydrocracked products into at least a gaseous fraction and a liquid fraction, contacting the liquid fraction with a dewaxing catalyst under hydroisomerization conditions to obtain the dewaxed product, and optionally contacting the dewaxed product with a hydrofinishing catalyst under hydrofinishing conditions to obtain the hydrofinished dewaxed product.

[0010] A second process according to the present invention includes preparing a base oil having a viscosity index of about 100 or greater by contacting a base oil feed comprising a medium vacuum gas oil (MVGO) having a front-end cut temperature of about 700°F or greater and a back-end cut temperature of about 900°F or less with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracked product, separating the hydrocracked product into a gas fraction and a liquid fraction, dewaxing the liquid fraction to obtain a dewaxed product, and optionally hydrofinishing the dewaxed product to obtain a hydrofinished dewaxed product.

[0011] The present invention also relates to a combined process for preparing a base oil product from a base oil stock, the combined process combining a first process and a second process to prepare a base oil meeting Group II and / or Group III / III+ specifications. The combined process generally prepares a base oil from a base oil stock or a fraction thereof, the combined process comprising using an atmospheric resid fraction obtained from the base oil stock or a fraction thereof, separating the base oil stock or a fraction thereof and / or the base oil atmospheric resid fraction into narrow vacuum gas oil fractions having a front-end cut temperature of about 700°F or greater and a back-end cut temperature of about 900°F or less to form a medium vacuum gas oil (MVGO) fraction and a residual heavy VGO (HHVGO) fraction, and using the HHVGO fraction as the atmospheric resid fraction in the first process and / or using the MVGO fraction as the base oil stock in the second process.

[0012] It will be appreciated that the scope of the present invention is not limited by any representative illustrations attached to this disclosure, but is instead defined by the claims of this application. [Brief explanation of the drawings]

[0013] [Figure 1] 1 is a block diagram generally illustrating a prior art process for preparing a base oil product. [Figure 2a]1 illustrates generally in block diagram form one embodiment of a process for preparing a base oil product using a blend of VGO and atmospheric resid (VGO / AR) in accordance with the present invention. [Figure 2b] 1 is a block diagram generally illustrating one embodiment of a process for preparing Group III / III+ base oil products using an MVGO fraction obtained from atmospheric residua and for preparing Group II base oil products using a mixture of VGO and HHVGO residual fractions obtained from atmospheric residua (VGO / HHVGO) in accordance with the present invention. [Figure 3a] 1 is a process diagram illustrating one embodiment of a process for preparing a base oil product according to the present invention as described in the Examples. [Figure 3b] 1 is a process diagram illustrating one embodiment of a process for preparing a base oil product according to the present invention as described in the Examples. [Figure 4] 1 is a process diagram illustrating one embodiment of a process for preparing a base oil product according to the present invention as described in the Examples. [Figure 5] 1 is a process diagram illustrating one embodiment of a process for preparing a base oil product according to the present invention as described in the Examples. DETAILED DESCRIPTION OF THE INVENTION

[0014] While embodiments of one or more aspects are illustrated herein, the disclosed processes may be implemented using any number of techniques. The present disclosure is not limited to the exemplary or specific embodiments, drawings, and techniques shown herein, including any example designs and embodiments illustrated and described herein, but may be modified within the scope of the appended claims and their full range of equivalents.

[0015] Unless otherwise specified, the following terms, terminology, and definitions are applicable to this disclosure. When a term is used in this disclosure but is not expressly defined herein, the definition in the IUPAC Compendium of Chemical Terminology, 2nd ed. (1997) may be applied, provided that the definition does not conflict with other disclosures or definitions applicable herein or render any claim to which it applies ambiguous or unenforceable. To the extent that any definition or usage provided by any document incorporated by reference herein conflicts with a definition or usage provided herein, it will be understood that the definition or usage provided herein shall apply.

[0016] "API base oil categories" are classifications of base oils that meet different criteria as shown in Table 1. [Table 1]

[0017] "API gravity" refers to the specific gravity of a petroleum feedstock or product relative to water, as determined by ASTM D4052-11 or ASTM D1298.

[0018] "ISO-VG" refers to the viscosity classification recommended for industrial use, as defined by IS03448:1992.

[0019] "Viscosity Index" (VI) describes the temperature dependence of a lubricant, which is determined by ASTM D2270-10 (E2011).

[0020] "Aromatic extraction" is part of the process used to produce solvent-neutral base oil. During aromatic extraction, vacuum gas oil, deasphalted oil, or a mixture thereof is extracted using a solvent in a solvent extraction unit. This aromatic extraction creates a waxy raffinate, which, after evaporation of the solvent, creates an aromatic extract.

[0021] "Atmospheric resid" or "atmospheric residuum" (AR) is the product of crude oil distillation at atmospheric pressure, from which volatiles have been removed during distillation. AR cuts are typically obtained using a cut temperature of 650°F (maximum 680°F).

[0022] "Vacuum gas oil" (VGO) is a by-product obtained from the vacuum distillation of crude oil that can be sent to a hydroprocessing unit or subjected to aromatic extraction for upgrading into base oils. VGO generally contains hydrocarbons with a boiling range distribution at 0.101 MPa between 343°C (649°F) and 538°C (1000°F).

[0023] "Deasphalted oil" (DAO) generally refers to the residual oil obtained from a vacuum distillation unit, which has been deasphalted in a solvent deasphalting process. Solvent deasphalting in refineries is described in J. Speight, Synthetic Fuels Handbook, ISBN 007149023X, 2008, pages 64, 85-85, and 121.

[0024] "Process," "treated," "improve," "improving," and "improved," when used in connection with an oil feed, describe that the feed is or has been subjected to hydroprocessing or that a material or crude product is obtained with a reduction in the molecular weight of the feed, a reduction in the boiling range of the feed, a reduction in the concentration of asphaltenes, a reduction in the concentration of hydrocarbon free radicals, and / or a reduction in the content of impurities (such as sulfur, nitrogen, oxygen, halides, and metals).

[0025] "Solvent dewaxing" is a process in which paraffins are dewaxed by crystallizing them at low temperatures and separating them by filtration. Solvent dewaxing produces dewaxed oil and soft wax. The dewaxed oil can be further subjected to hydrofinishing to obtain base oil.

[0026] "Hydroprocessing" refers to a process in which a carbonaceous feedstock is contacted with hydrogen and a catalyst at elevated temperatures and pressures for the purpose of removing undesirable impurities and / or converting the feedstock into desired products. Examples of hydroprocessing processes include hydrocracking, hydrotreating, catalytic dewaxing, and hydrofinishing.

[0027] "Hydrocracking" refers to a process in which hydrocarbon cracking / fragmentation (e.g., conversion of heavier hydrocarbons to lighter hydrocarbons, or conversion of aromatics and / or cycloparaffins (naphthenes) to acyclic branched paraffins) occurs along with hydrogenation and dehydrogenation.

[0028] "Hydrotreating" refers to the process of converting a sulfur- and / or nitrogen-containing hydrocarbon feedstock into hydrocarbon products with reduced sulfur and / or nitrogen content, typically in conjunction with hydrocracking, which produces hydrogen sulfide and / or ammonia (respectively) as by-products from the sulfur and / or nitrogen.

[0029] "Catalytic dewaxing" or hydroisomerization refers to the process of isomerizing normal paraffins to their more branched counterparts in the presence of hydrogen and a catalyst.

[0030] "Hydrofinishing" refers to a process intended to improve the oxidative stability, UV stability, and appearance of the hydrofinished product by removing trace amounts of aromatics, olefins, color bodies, and solvents. As used in this disclosure, the term UV stability refers to the stability of the test hydrocarbon when exposed to UV light and oxygen. Instability is indicated by the formation of visible precipitate (usually seen as clumps or haze) or the development of color upon exposure to UV light and air. A general description of hydrofinishing can be found in U.S. Pat. Nos. 3,852,207 and 4,673,487.

[0031] The terms "Hydrogen" or "hydrogen" refer to hydrogen itself and / or a compound or compounds that are a source of hydrogen.

[0032] "Cut temperature" refers to the temperature on the true boiling point (TBP) curve at which a given degree of separation is reached.

[0033] "TBP" refers to the boiling point of a hydrocarbonaceous feed or product, as determined by simulated distillation (SimDist) per ASTM D2887-13.

[0034] "Hydrocarbonaceous," "hydrocarbon," and similar terms refer to compounds containing only carbon and hydrogen atoms. Other identifying terms may be used to indicate the presence of a particular group, if any, in the hydrocarbon (e.g., halogenated hydrocarbon indicates the presence of one or more halogen atoms replacing an equal number of hydrogen atoms in the hydrocarbon).

[0035] "Group IIB" or "Group IIB metals" refers to zinc (Zn), cadmium (Cd), mercury (Hg), and combinations thereof, in either elemental, compound, or ionic form.

[0036] "Group IVA" or "Group IVA metal" refers to germanium (Ge), tin (Sn), or lead (Pb), and combinations thereof, in either elemental, compound, or ionic form.

[0037] "Group V metal" refers to vanadium (V), niobium (Nb), tantalum (Ta), and combinations thereof in elemental, compound, or ionic form.

[0038] "Group VIB" or "Group VIB metal" refers to chromium (Cr), molybdenum (Mo), tungsten (W), and combinations thereof, in either elemental, compound, or ionic form.

[0039] "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 either elemental, compound, or ionic form.

[0040] The term "support," specifically as used in the term "catalyst support," refers to a conventional, high-surface-area, typically solid material to which catalytic material is bound. Support materials can be inert or participate in catalytic reactions and can be porous or non-porous. Typical catalyst supports include various types of carbon, alumina, silica, and silica-alumina (e.g., amorphous silica-aluminates, zeolites, alumina-boria, silica-alumina-magnesia, silica-alumina-titania, and materials obtained by adding other zeolites and other complex oxides thereto).

[0041] "Molecular sieve" refers to a material having uniform molecular-dimensional pores within a framework structure such that, depending on the type of molecular sieve, only certain molecules can access the pore structure of the molecular sieve while other molecules are excluded (such access and exclusion occurs due to, for example, molecular size and / or reactivity). Zeolites, crystalline aluminophosphates, and crystalline silicoaluminophosphates are representative examples of molecular sieves.

[0042] W220 and W600 refer to waxy medium and heavy Group II base oil product grades, with W220 referring to a waxy medium base oil product having an apparent viscosity of about 6 cSt at 100° C. and W600 referring to a waxy heavy base oil product having an apparent viscosity of about 12 cSt at 100° C. Typical test data for Group II base oils after dewaxing are as follows: [Table 2]

[0043] In this disclosure, compositions and methods or processes are often described as "comprising" various components or steps, but unless otherwise stated, such compositions and methods can also "consist essentially of" or "consist of" such various components or steps.

[0044] The terms "a," "an," and "the" are intended to include plural alternatives (e.g., at least one). For example, disclosure of a "transition metal" or an "alkali metal" is intended to encompass one transition metal or alkali metal, or a mixture or combination of multiple transition metals or alkali metals, unless otherwise specified.

[0045] All numerical values ​​set forth in the detailed description and claims herein are modified by the prefix "about" or "approximately" to account for experimental error and variations that would be expected by one of ordinary skill in the art.

[0046] In one aspect, the present invention is a process for preparing a base oil product, the process comprising: combining an atmospheric resid feed and a base oil feed to form a base oil feedstream; contacting the base oil feedstream with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracked product; separating the hydrocracking product into a gas fraction and a liquid fraction; contacting the liquid fraction with a dewaxing catalyst under hydroisomerization conditions to obtain a dewaxed product; and optionally contacting the dewaxed product with a hydrofinishing catalyst under hydrofinishing conditions to obtain a hydrofinished dewaxed product; Includes.

[0047] Base stocks generally meet one or more of the following property requirements: an API gravity in the range of 15 to 40, or 15 to 30, or 15 to 25, or at least 15, or at least 17, optionally less than that of the atmospheric resid feed; a VI in the range of 30-90, or 40-90, or 50-90, or 50-80, optionally less than the VI of the atmospheric resid feed; a viscosity at 100°C in the range of 3 to 30 cSt, 3 to 25 cSt, or 3 to 20 cSt, or at least 3 cSt, or at least 4 cSt; a viscosity at 70°C in the range of 5 to 25 cSt, or 5 to 20 cSt, or 5 to 15 cSt, or at least 5 cSt, or at least 6 cSt; a thermal C7 asphaltene content in the range of 0.01 to 0.3 wt%, or 0.01 to 0.2 wt%, or 0.02 to 0.15 wt%, or less than 0.3 wt%, or less than 0.2 wt%; a wax content in the range of 5 to 40 wt%, or 5 to 30 wt%, or 10 to 25 wt%, or at least 5 wt%, or at least 10 wt%, or at least 15 wt%, or optionally exceeding the wax content of the base oil feed; 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; a sulfur content of 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 in the range of 100-8000 ppm, or 100-6000 ppm, or 100-4000 ppm, or 100-2000 ppm, or 100-1000 ppm, or 100-500 ppm, or 100-200 ppm; and / or The 1050+°F content is within the range of 5-50 wt%, or 5-40 wt%, or 8-40 wt%, or optionally greater than the 1050+°F content of the base oil feed.

[0048] Suitable base stocks can be derived from any crude oil feed or fraction thereof, including hydroprocessed intermediate streams or other feeds. Generally, base stocks include materials boiling within the base oil range. Feedstocks can include atmospheric and vacuum residua, whole crude oils, and paraffin-based crude oils from a variety of sources.

[0049] Atmospheric residue (AR) feedstocks generally meet one or more of the following characteristic conditions: an API gravity in the range of 20 to 60, or 20 to 45, or 25 to 45, or at least 20, or at least 22, or optionally above the API of the base oil feed; a VI in the range of 50 to 200, or 70 to 190, or 90 to 180, or at least 80, or optionally above the VI of the base oil feed; a viscosity at 100°C in the range of 3 to 30 cSt, 3 to 25 cSt, or 3 to 20 cSt, or at least 3 cSt, or at least 4 cSt; a viscosity at 70°C in the range of 5 to 25 cSt, or 5 to 20 cSt, or 5 to 15 cSt, or at least 5 cSt, or at least 6 cSt; a thermal C7 asphaltene content in the range of 0.01 to 0.3 wt%, or 0.01 to 0.2 wt%, or 0.02 to 0.15 wt%, or less than 0.3 wt%, or less than 0.2 wt%; a wax content in the range of 5 to 40 wt%, or 5 to 30 wt%, or 10 to 25 wt%, or at least 5 wt%, or at least 10 wt%, or at least 15 wt%, or optionally exceeding the wax content of the base oil feed; 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; a sulfur content of 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 in the range of 100-8000 ppm, or 100-6000 ppm, or 100-4000 ppm, or 100-2000 ppm, or 100-1000 ppm, or 100-500 ppm, or 100-200 ppm; and / or The 1050+°F content is within the range of 5-50 wt%, or 5-40 wt%, or 8-40 wt%, or optionally greater than the 1050+°F content of the base oil feed.

[0050] In some embodiments, AR feedstocks having the property characteristics described herein can be advantageously obtained from light tight oil (LTO, e.g., shale oil (typically API greater than 45)). Suitable feedstocks can be Permian Basin feedstocks and those from other locations, including Eagle Ford, Avalon, Magellan, Buckeye, and the like.

[0051] Both the base oil stock and atmospheric resid stock may have any of the aforementioned properties falling within any of the broad and narrower ranges stated, and combinations of such ranges.

[0052] The base oil feedstream typically comprises 10-60 wt% atmospheric residua feed and 40-90 wt% base oil feed, or 10-40 wt% atmospheric residua feed and 60-90 wt% base oil feed, or 10-30 wt% atmospheric residua feed and 70-90 wt% base oil feed, or 30-60 wt% atmospheric residua feed and 40-70 wt% base oil feed, or 40-60 wt% atmospheric residua feed and 40-60 wt% base oil feed.

[0053] In certain embodiments, the base oil feedstream does not contain any added whole crude feed, and / or does not contain any vacuum resid feed, and / or does not contain any deasphalted feed components, and / or contains only atmospheric resid feed and base oil feed.

[0054] Although not limited to a run-through process, the process need not include recycling the liquid feed as part of the base oil feedstream, or as either or both of the atmospheric resid feed and the base oil feed, although in certain embodiments it may be desirable to recycle one or more intermediate streams.

[0055] The base oil feed may comprise, consist essentially of, or consist of vacuum gas oil, which may be a heavy vacuum gas oil obtained by cutting vacuum gas oil into a light fraction and a heavy fraction, the heavy fraction having a cut temperature range of about 950-1050°F.

[0056] The dewaxed and / or hydrofinished dewaxed products are typically obtained as a light base oil product and a heavy base oil product. The light base oil product generally has an apparent viscosity in the range of 4-8 cSt or 5-7 cSt at 100° C., and / or the heavy base oil product generally has an apparent viscosity in the range of 10-14 cSt or 11-13 cSt at 100° C. The dewaxed product may be further separated into at least a light product having an apparent viscosity of about 6 cSt at 100° C. and / or a heavy product having an apparent viscosity of about 12 cSt at 100° C., or a combination thereof.

[0057] One advantage associated with the process is that the yield of heavy base oil product relative to light base oil product may be increased by at least about 2 vol% or at least about 5 vol% (liquid volume %) compared to the same process without an atmospheric resid feed in the lubricant feedstream. In some embodiments, the yield of heavy base oil product may be increased by at least about 10 vol%, or at least about 20 vol%, or at least about 30 vol%, or at least about 40 vol% compared to the same process without an atmospheric resid feed in the base oil feedstream.

[0058] In another aspect, the present invention relates to a method for modifying a conventional or existing base oil process. Specifically, a base oil process comprising subjecting a base oil feedstream to hydrocracking and dewaxing steps to form a dewaxed product comprising lighter and heavier products may be modified in accordance with the present invention by combining an atmospheric resid feed with the base oil feed to form the base oil feedstream, and subjecting the base oil feedstream comprising the atmospheric resid feed to the hydrocracking and dewaxing steps of the base oil process to obtain the dewaxed product. The dewaxed product may optionally be further contacted with a hydrofinishing catalyst under hydrofinishing conditions to obtain the hydrofinished dewaxed product.

[0059] The present invention further relates to a process for preparing a base oil, the process comprising contacting a base oil feed having a viscosity index of about 100 or greater with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracked product, wherein the base oil feed comprises a vacuum gas oil having a front-end cut temperature of about 700°F or greater and a back-end cut temperature of about 900°F or less; separating the hydrocracked product into a gas fraction and a liquid fraction; contacting the liquid fraction with a dewaxing catalyst under hydroisomerization conditions to obtain a dewaxed product; and optionally contacting the dewaxed product with a hydrofinishing catalyst under hydrofinishing conditions to obtain a hydrofinished dewaxed product, wherein after dewaxing the dewaxed product and / or hydrofinished dewaxed product has a viscosity index of 120 or greater. After dewaxing, the dewaxed product and / or hydrofinished dewaxed product may have a viscosity index of 130 or greater, or 135 or greater, or 140 or greater. The hydrocracking product may have a viscosity index of at least about 135, or at least about 140, or at least about 145, or at least about 150. The dewaxed product prepared by the process may be a Group III or Group III+ product.

[0060] Compared to using a conventional VGO feedstock, the use of a vacuum gas oil having a front-end cut temperature of about 700°F or greater and a back-end cut temperature of about 900°F or less (referred to herein as medium vacuum gas oil (MVGO)) improves the yield of Group III or Group III+ waxy products by at least about 3% by volume when the MVGO has a viscosity of 4 cSt at 100°C compared to the same process without MVGO as the base oil feedstock.

[0061] The present invention also relates to a process that combines two process aspects, i.e., in which a feedstock is used to obtain a narrow cut fraction and the same or a different feedstock is used for the atmospheric residue fraction. The combined process for preparing base oils from a base stock or a fraction thereof includes obtaining an atmospheric residue fraction from the base stock or a fraction thereof, separating the base stock or a fraction thereof and / or the base oil atmospheric residue fraction into narrow cut vacuum gas oil fractions having a front-end cut temperature of about 700°F or greater and a back-end cut temperature of about 900°F or less to form an MVGO fraction and a residual HHVGO fraction, using the HHVGO fraction as the atmospheric residue feed in the first process to prepare a dewaxed product and / or a hydrofinished dewaxed product, and / or using the MVGO fraction as the base stock in the second process to prepare a dewaxed product and / or a hydrofinished dewaxed product having a dewaxed viscosity index of 120 or greater. In certain embodiments, the base oil feed may comprise a tight oil, specifically a light tight oil or fraction thereof. Narrow cutoff vacuum gas oil fractions may also be derived from atmospheric resid fractions, including atmospheric resid fractions derived from light tight oil.

[0062] Advantageously, fractionation of an AR feedstock into an MVGO fraction and an HHVGO fraction provides the ability to produce Group III / III+ base oil products, while still allowing the HHVGO fraction to be used with conventional VGO base oil stocks to produce Group II base oil products. In some embodiments, the use of MVGO in the production of Group III / III+ base oil products improves the yield of such products.

[0063] Figure 2a illustrates an example of a method or process according to one embodiment of the present invention, which uses conventional hydrotreating, hydrocracking, hydrodewaxing, and hydrofinishing process steps, conditions, and catalysts to obtain a base oil. In comparison to the prior art base oil process diagram shown in Figure 1, Figure 2a illustrates the use of a VGO and atmospheric residue (AR) feedstock blend where a VGO base oil feedstock would typically be used in conventional processes. Figure 2b further illustrates the use of the AR feedstock to form a medium vacuum gas oil fraction (MVGO) and a heavy VGO fraction (HHVGO), with the MVGO fraction feedstream being used to produce Group III / III+ base oil products and the HHVGO fraction being combined with a conventional VGO base oil feedstock to produce a Group II base oil product.

[0064] Catalysts suitable for use as hydrocracking, dewaxing, and hydrofinishing catalysts in processes and methods, and related process conditions, are described in many publications, including, for example, U.S. Patent Publication Nos. 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, No. 6,860,987, 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, Nos. 7,838,696, 7,910,761, 7,931,799, 7,964,524, 7,964,525, 7,964,526, 8,058,203, 10,196,575, WO2017 / 044210, and others.

[0065] Suitable catalysts for hydrocracking include, for example, materials having hydrogenation-dehydrogenation activity combined with an active cracking component support. Such catalysts are well described in numerous patents and references. Examples of cracking component supports include silica-alumina, silica-zirconia oxide composites, acid-treated clays, crystalline aluminosilicate zeolite molecular sieves (such as zeolite A, faujasite, zeolite X, and zeolite Y), and combinations thereof. The hydrogenation-dehydrogenation component of the catalyst preferably comprises a metal selected from Group VIII metals and their compounds and Group VIB metals and their compounds. Preferred Group VIII components include cobalt and nickel, particularly the oxides and sulfides thereof. Preferred Group VIB components are the oxides and sulfides of molybdenum and tungsten. Examples of hydrocracking catalysts contemplated as suitable for use in the hydrocracking process step are nickel-tungsten-silica-alumina, nickel-molybdenum-silica-alumina, and cobalt-molybdenum-silica-alumina. Depending on their composition and preparation, such catalysts can vary in their hydrogenation activity, their cracking activity, and their ability to maintain high activity over extended periods of use.

[0066] Typical hydrocracking reaction conditions include, for example, a temperature of 450°F to 900°F (232°C to 482°C) (e.g., 650°F to 850°F (343°C to 454°C)), a pressure of 500 psig to 5000 psig (3.5 MPa to 34.5 MPa gauge) (e.g., 1500 psig to 3500 psig (10.4 MPa to 24.2 MPa gauge)), and a 0.1 hour reaction time. -1~ 15 hours -1 (v / v) (e.g., 0.25 h -1 ~2.5 hours -1 ) liquid reactant feed rate (liquid hourly space velocity (LHSV)), hydrogen feed ratio (H2 / hydrocarbon ratio) of liquid base oil (lubricant) feedstock 500 SCF / bbl to 5000 SCF / bbl (89 to 890 m 3 H2 / m 3feed), and / or hydrogen partial pressures greater than 200 psig (e.g., 500-3000 psig), and hydrogen recycle ratios greater than 500 SCF / B (e.g., 1000-7000 SCF / B).

[0067] Hydrodewaxing is primarily used to lower the pour point and / or cloud point of a base oil by removing wax from the base oil. Dewaxing typically utilizes a catalytic process for treating wax, and the dewaxed feedstock is generally upgraded prior to dewaxing to increase the viscosity index, reduce the aromatic and heteroatom content, and reduce the amount of low-boiling components in the dewaxed feedstock. Some dewaxing catalysts achieve wax conversion reactions by cracking waxy molecules into molecules with reduced molecular weights. Other dewaxing processes convert wax contained in hydrocarbon feedstocks subjected to such processes by wax isomerization, resulting in isomerized molecules with reduced pour points compared to their non-isomerized counterparts. As used herein, isomerization encompasses hydroisomerization processes for using hydrogen in the isomerization of waxy molecules under catalytic hydroisomerization conditions.

[0068] Dewaxing generally involves treating a dewaxed feedstock by hydroisomerization to convert at least n-paraffins and form an isomerized product comprising isoparaffins. Suitable isomerization catalysts for use in the dewaxing step can include, but are not limited to, Pt and / or Pd supported on a support. Suitable supports include, but are not limited to, zeolite CIT-1, zeolite IM-5, zeolite SSZ-20, zeolite SSZ-23, zeolite SSZ-24, zeolite SSZ-25, zeolite SSZ-26, zeolite SSZ-31, zeolite SSZ-32, zeolite SSZ-33, zeolite SSZ-35, zeolite SSZ-36, zeolite SSZ-37, zeolite SSZ-41, zeolite SSZ-42, Zeolite SSZ-43, Zeolite SSZ-44, Zeolite SSZ-46, Zeolite SSZ-47, Zeolite SSZ-48, Zeolite SSZ-51, Zeolite SSZ-56, Zeolite SSZ-57, Zeolite SSZ-58, Zeolite SSZ-59, Zeolite SSZ-60, Zeolite SSZ-61, Zeolite SSZ-63, Zeolite SSZ-64, Zeolite SSZ-65, Zeolite SSZ-67, Zeolite SSZ-68, Zeolite Zeolite SSZ-69, Zeolite SSZ-70, Zeolite SSZ-71, Zeolite SSZ-74, Zeolite SSZ-75, Zeolite SSZ-76, Zeolite SSZ-78, Zeolite SSZ-81, Zeolite SSZ-82, Zeolite SSZ-83, Zeolite SSZ-86, Zeolite SUZ-4, Zeolite TNU-9, Zeolite ZSM-S, Zeolite ZSM-12, Zeolite ZSM-22, Zeolite ZSM-23, Zeolite ZS Included are M-35, zeolite ZSM-48, EMT-type zeolites, FAU-type zeolites, FER-type zeolites, MEL-type zeolites, MFI-type zeolites, MTT-type zeolites, MTW-type zeolites, MWW-type zeolites, MRE-type zeolites, TON-type zeolites, and other molecular sieve materials based on crystalline aluminophosphates, such as SM-3, SM-7, SAPO-11, SAPO-31, SAPO-41, MAPO-11, and MAPO-31.Isomerization may also use Pt and / or Pd catalysts supported on acidic support materials, such as beta or zeolite Y molecular sieves, silica, alumina, silica-alumina, and combinations thereof. Suitable isomerization catalysts are well described in the patent literature, see, for example, U.S. Pat. Nos. 4,859,312, 5,158,665, and 5,300,210.

[0069] Hydrodewaxing conditions generally depend on the feedstock used, the catalyst used, whether the catalyst is sulfided, the desired yield, and the desired base oil properties. Typical conditions include temperatures of 500°F to 775°F (260°C to 413°C), pressures of 15 psig to 3000 psig (0.10 MPa to 20.68 MPa gauge), and a 0.25 hour hydrodewaxing period. -1~ 20 hours -1 LHSV of 2000 SCF / bbl to 30,000 SCF / bbl (356 to 5340 m 3 H2 / m 3 The hydrogen to feed ratio (of the product) is included. Typically, hydrogen will be separated from the product and recycled to the isomerization zone. Suitable conditions and processes for dewaxing are described, for example, in U.S. Patent Nos. 5,135,638, 5,282,958, and 7,282,134.

[0070] The waxy products W220 and W600 can be dewaxed to form 220N and 600N products, which may be suitable (or highly suitable) for use as lubricant base oils or in lubricants. For example, these dewaxed products can be blended or blended with existing lubricant base oils to create new base oils or modify the properties of existing base oils to meet specific target conditions (such as viscosity or Noack targets) for specific base oil grades, such as 220N and 600N. Isomerization and blending can be used to adjust and maintain the appropriate pour and cloud points of the base oils. Normal paraffins can also be blended with other base oil components before undergoing catalytic isomerization, including blending normal paraffins with isomerized products. The lubricant base oils that may be produced in the dewaxing step can be treated in a separation step to remove light ends. The lubricant base oil may be further processed by distillation using atmospheric distillation and optionally vacuum distillation to produce a lubricant base oil.

[0071] Typical hydrotreating conditions vary widely. Generally, the overall LHSV is about 0.25 hours. -1~ 10 hours -1 (v / v), or alternatively for about 0.5 hours -1~ 1.5 hours -1 The total pressure is between 200 psig and 3000 psig, or alternatively between about 500 psia and about 2500 psia. The hydrogen feed ratio (H2 / hydrocarbon ratio) is typically between 500 SCF / bbl and 5000 SCF / bbl (89-890 m 3 H2 / m 3 feedstock), often between 1000 and 3500 SCF / Bbl. The reaction temperature in the reactor will typically be within the range of about 300°F to about 750°F (about 150°C to about 400°C), or alternatively, within the range of 450°F to 725°F (230°C to 385°C).

[0072] In practical terms, layered catalyst systems containing hydrotreating (HDT, HDM, DEMET, etc.), hydrocracking (HCR), hydrodewaxing (HDW), and hydrofinishing (HFN) catalysts can be utilized to produce intermediate base oils and / or finished base oils using single or multiple reactor systems. A typical configuration includes two reactors, with the first reactor containing layered catalysts that provide DEMET activity, HDT pretreatment activity, HCR activity, and / or HDW activity. Different catalysts that perform similar functions (e.g., with different levels of hydrocracking activity) can also be used, with such catalysts being present, for example, in different layers within a single reactor or in separate reactors. [Example]

[0073] Vacuum gas oil (VGO) and atmospheric residue (AR) samples were obtained from commercially available sources and used in the process schemes shown in Figures 3a, 3b, 4, and 5. Figures 3a and 3b show the large process research unit configurations typically used to evaluate large quantities of feedstock when available. Figures 4 and 5 show the smaller bench-scale units used to evaluate smaller quantities of feedstock, and this small bench-scale unit was primarily used for the evaluation of all AR samples.

[0074] In the research unit process, LHSV -1 The downstream reactor R2 was maintained at a temperature 20°F higher than the upstream reactor R1 using conditions of 0.5, reactor H2 partial pressure of 1750 psia, hydrogen feed gas oil (recycle) ratio of 4500 scfb, and reactor temperatures in the range of 700-770°F. The temperature of the downstream reactor R2 was maintained 20°F higher than that of the upstream reactor R1. The temperature ramp profiles were controlled to achieve ΔT of 120°F and 40°F for R1 and R2, respectively. The target viscosity index (VI) of the waxy product was 109 (W220) at 6.0 cSt (100°C) and 109 (W600) at 11.8 cSt (100°C).

[0075] In bench-scale processes, LHSV -1The following conditions were used: 0.5, reactor pressure of 1850 psig, hydrogen feed gas oil ratio of 4500 scfb, and reactor temperature in the range of 700-770+°F. The temperature of the downstream reactor R2 was maintained 20°F higher than the upstream reactor R1. The target viscosity index (VI) of the waxy product was 109 (220R) at 6.1 cSt (100°C) and 109 (600R) at 11.8 cSt (100°C).

[0076] The catalyst loading in each of reactors R1 and R2 (according to Figures 3a, 3b, 4, and 5, respectively) followed a conventional base oil production scheme, including layered hydrometallation, hydrotreating, and hydrocracking catalysts. A typical configuration included a layered catalyst system for both R1 and R2, including one or more DEMET layers, high activity HCR / HDT, HCR, and low activity HCR catalysts.

[0077] Figures 3a, 3b, 4, and 5 each show feed stream 10 and H2 inlet 11 (to reactor R1 and reactor R2, respectively), as well as other intermediate flow streams 20, intermediate flow stream 30, H2 recycle stream 31, and total liquid product (WLP) stream 32, which is sent to separators and / or condensers (C1-C4, S1, and V3) to provide the respective product streams shown in each figure (C2B, C3B, CO, CB, STO, STB, V3O, and V3B), as described in the Examples below.

[0078] Example 1 - Vacuum Gas Oil (VGO) Feed (Comparative Feed) A sample of vacuum gas oil (VGO) feedstock obtained from a commercially available source was used to produce base oil products and analyzed as a comparative base case. This VGO feedstock was used in the following examples according to the process configurations shown in Figures 3a, 3b, 4, and 5. Table 1 lists the properties of this VGO feedstock (sample ID 2358). [Table 3]

[0079] Example 2 - Atmospheric Residue (AR) Feed Characterization Atmospheric resid samples (AR1-AR5) were obtained from commercially available sources and analyzed. These AR samples were used as feedstock components in accordance with the present invention. Table 2 shows the properties of these AR samples. [Table 4]

[0080] Example 3 - Properties of Atmospheric Residue (AR) and Vacuum Gas Oil (VGO) Feed Blends The atmospheric residue samples (AR1-AR5) from Example 2 were blended on a weight basis with the vacuum gas oil (VGO) feedstock from Example 1, and these blends were analyzed. These AR / VGO blend samples were used as exemplary feedstocks in accordance with the present invention. Table 3 lists the properties of these AR / VGO blend samples. [Table 5]

[0081] Example 4 - Evaluation of the production of Group II base oils from blends of atmospheric residue (AR) and vacuum gas oil (VGO) feedstocks The blend feedstock of Example 3 (a blend of atmospheric resid samples AR1-AR5 and vacuum gas oil (VGO)) was evaluated for the production of Group II base oils according to the process shown in Figure 3b. As a comparison, Group II results were also obtained using the VGO feedstock of Example 1 (according to the process of Figure 3a).

[0082] In bench-scale processes, LHSV -1 The following conditions were used: 0.5, reactor pressure of 1850 psig, hydrogen feed gas oil ratio of 4500 scfb, and reactor temperature in the range of 700-770+°F. The temperature of the downstream reactor R2 was maintained 20°F higher than the upstream reactor R1. The target viscosity index (VI) of the waxy product was 109 (220R) at 6.1 cSt (100°C) and 109 (600R) at 11.8 cSt (100°C).

[0083] Table 4a shows the results comparing base oil production for VGO feedstock alone and AR1 / VGO blends, Table 4b shows the results for blends of AR2 and VGO and AR3 and VGO, and Table 4c shows the results for blends of AR4 and VGO and AR5 and VGO, with each set of results determined using the AR / VGO blend of Example 3.

[0084] As shown in Table 4a, using the AR1 / VGO blend as the lubricant process feed improved the yield of the heavy base oil product W600 to 57.5 vol.%, compared to 19.3 vol.% when the feed did not contain the atmospheric resid AR1 component. This improvement in heavy base oil yield is significant, even though the AR1 / VGO blend experienced some hydrocracking losses (about 15°F) and reduced HDN activity (above 19°F). The benefit of obtaining a high W600 yield suggests that improving the activity and robustness of the HDN catalyst system would also be beneficial, especially when the feedstock has a high nitrogen content. [Table 6-1] [Table 6-2] [Table 6-3] [Table 6-4]

[0085] Table 4b shows the results obtained for blends of atmospheric resid sample AR2 and atmospheric resid sample AR3 with vacuum gas oil (VGO). As shown, for the AR2 / VGO blend (90-326-3242-3266), both the waxy W600 recovery and the total waxy product recovery were significantly improved when targeting the same W220 VI (near 109): 36.6% vs. 18.6% waxy 600R yield, and 69.4% vs. 53.5% total waxy product yield. Although the resulting waxy product had an increased nitrogen content, it was possible to reduce the high N content of the product, as shown in 90-326-3098-3122, at the expense of the waxy W600R yield and the total waxy base oil yield (a 6% decrease in W600R yield and a 2% decrease in total waxy base oil yield).

[0086] Table 4b shows that using the AR3 / VGO blend (88-342-3726-3750) significantly improved the recovery of waxy W600R compared to the VGO feedstock alone (31.9% vs. 18.6%). The total recovery of waxy base oil remained the same, while the nitrogen content of the waxy product obtained from the AR3 / VGO blend was slightly higher.

[0087] Table 4c shows the results obtained for blends of atmospheric resid sample AR4 and atmospheric resid sample AR5 with vacuum gas oil (VGO). As shown, two separate experiments were carried out at different hydrocracking degrees for each of the VGO comparative feedstock and the AR4 / VGO and AR5 / VGO blends. [Table 7-1] [Table 7-2] [Table 8-1] [Table 8-2]

[0088] The results in Table 4c form the basis for a comparison of waxy base oil yields (shown in Table 4d) for AR2 / VGO, AR4 / VGO, and AR5 / VGO blends at a W220 viscosity index (VI) of 109. At a W220 VI of 109, the 50% AR2 / VGO blend feedstock improved waxy base oil yields compared to the VGO feedstock alone, resulting in a W600 yield of 33.7%, compared to 25.8% for the VGO feedstock alone without the atmospheric resid AR2 component. The AR2 / VGO blend resulted in a total waxy base oil yield of 68.7%, compared to 66.1% when the feedstock contained no AR2 blend components.

[0089] Even at 20% AR4 / VGO blends, there was an improvement in the yield of W600 from the AR4 / VGO blend compared to the VGO feedstock alone (28.4% vs. 25.8%), an improvement in the yield of W220 from the AR4 / VGO blend compared to the VGO feedstock alone (42.9% vs. 40.3%), and an improvement in the total yield of waxy base oil from the AR4 / VGO blend compared to the VGO feedstock alone (71.3% vs. 66.1%).

[0090] Similarly, at 20% AR5 / VGO, there was an improvement in the yield of W220 from the AR5 / VGO blend compared to the VGO feedstock alone (44.4% vs. 40.3%) and an improvement in the overall yield of waxy base oil W600 from the AR5 / VGO blend compared to the VGO feedstock alone (68.1% vs. 66.1%). [Table 9]

[0091] Example 5 - Evaluation of Atmospheric Residue (AR) to Provide Medium Grade Vacuum Gas Oil (MVGO) for the Production of Group III / III+ Base Oils Atmospheric residue (AR) samples were evaluated to provide medium-grade vacuum gas oils (MVGO) for use in the production of Group III / III+ base oils. MVGO samples were obtained as distillation cuts from the corresponding AR samples within the following ranges: AR2 cut range 717-876°F, AR4 cut range 725-882°F, and AR5 cut range 716-882°F. Table 5a shows the properties of the AR samples (AR2, AR4, and AR5) and the properties of the corresponding MVGOs obtained by the cuts (MVGO2, MVGO4, and MVGO5). Properties of a comparative vacuum gas oil (VGO) are also included.

[0092] MVGO from three atmospheric residues (ARs) was evaluated for the production of Group III base oils at different degrees of dewaxing with different waxy viscosity indices (VI) at a kinematic viscosity at 100°C (KV100) of approximately 4 cSt using the process configuration in Figure 4. Table 5b summarizes the yields for the comparative case of VGO alone, as well as the yields for MVGO obtained from AR2, AR4, and AR5 feedstocks (designated MVGO2, MVGO4, and MVGO5 feedstocks, respectively). [Table 10-1] [Table 10-2] [Table 11-1] [Table 11-2]

[0093] Example 6 - Evaluation of Medium Vacuum Gas Oil (MVGO) Fractions Obtained from Atmospheric Resid Feed AR3 Samples of atmospheric resid feedstock sample AR3 were evaluated to provide medium grade vacuum gas oil (MVGO) for use in the production of Group III / III+ base oils. MVGO samples were obtained from the corresponding AR3 samples as a distillation cut in the range of 725-895°F (designated MVGO3b) (a broad temperature range cut) and a distillation cut in the range of 725-855°F (designated MVGO3n) (a narrow temperature range cut).

[0094] Table 6 shows the results of using MVGO3b and MVGO3n feedstocks to produce Group III 4 cSt base oil using the process configuration in Figure 3a. Comparative VGO properties are also included. Both MVGO3b and MVGO3n MVGO feedstocks improved Group III waxy product yields in the production of 4 cSt base oil, with a 4.5 vol% increase for the wide-cut MVGO3b and a 6.6 vol% increase for the narrow-cut MVGO3n compared to using the VGO feedstock. [Table 12]

[0095] Example 7 - Evaluation of Atmospheric Residue (AR)-Derived Heavy Heavy Vacuum Gas Oil (HHVGO) Fractions to Produce Group II Base Oils As described in Example 5, a sample of atmospheric resid (AR) was used to obtain a medium grade vacuum gas oil (MVGO) for use in producing Group III / III+ base oils. The residual fraction absent the MVGO fraction was designated the HHVGO fraction. This HHVGO fraction was evaluated for use as a feed component to be blended with vacuum gas oil (VGO) to produce Group II base oils.

[0096] Table 7a shows the properties of the HHVGO samples (HHVGO2, HHVGO4, and HHVGO5) and the 9% HHVGO / VGO and 9% HHVGO / VGO blends. Properties of comparative VGO raw materials are also shown. [Table 13-1] [Table 13-2]

[0097] Table 7b shows the results of using a HHVGO / VGO blend feedstock to produce Group II base oils using the process configuration of Figure 5. Results for a comparative vacuum gas oil (VGO) are also included. These results are further summarized in Table 7c. Both HHVGO feedstocks, i.e., 9% HHVGO2 / VGO and 9% HHVGO4 / VGO, produced comparable Group II waxy base oil product yields compared to using the VGO feedstock alone. Therefore, the combination of using an MVGO cut to produce Group III base oils and the residual HHVGO fraction to produce Group II base oils offers technical and economic advantages compared to using a vacuum gas oil feedstock. [Table 14-1] [Table 14-2] [Table 15-1] [Table 15-2] [Table 16]

[0098] It will be recognized that the foregoing description of one or more embodiments of the invention has been intended for purposes of illustration and that variations may be employed which will still encompass the essence of the invention. Reference should be made to the following claims in determining the scope of the invention.

[0099] For purposes of United States patent practice, and in other permissible patent offices, all patents and publications cited in the foregoing description of the invention are hereby incorporated by reference, to the extent that any information contained therein is consistent with and / or supplements the foregoing disclosure.

Claims

1. 1. A process for preparing a base oil, said process comprising: combining an atmospheric resid feed and a base oil feed to form a base oil feedstream; contacting the base oil feedstream with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracked product; separating the hydrocracking product into a gas fraction and a liquid fraction; contacting the liquid fraction with a dewaxing catalyst under hydroisomerization conditions to obtain a dewaxed product; and optionally contacting the dewaxed product with a hydrofinishing catalyst under hydrofinishing conditions to obtain a hydrofinished dewaxed product; The process comprising:

2. 10. The process of claim 1, wherein the atmospheric resid feed meets one or more of the following conditions: an API gravity in the range of 20 to 60, or 20 to 45, or 25 to 45, or at least 20, or at least 22, or optionally above the API gravity of said base oil feed; a VI in the range of 50 to 200, or 70 to 190, or 90 to 180, or at least 80, or optionally above the VI of said base oil feed; a viscosity at 100°C in the range of 3 to 30 cSt, or 3 to 25 cSt, or 3 to 20 cSt, or at least 3 cSt, or at least 4 cSt; a viscosity at 70°C in the range of 5 to 25 cSt, or 5 to 20 cSt, or 5 to 15 cSt, or at least 5 cSt, or at least 6 cSt; fever C ７ an asphaltene content in the range of 0.01 to 0.3 wt%, or 0.01 to 0.2 wt%, or 0.02 to 0.15 wt%, or less than 0.3 wt%, or less than 0.2 wt%; a wax content in the range of 5 to 40 wt%, or 5 to 30 wt%, or 10 to 25 wt%, or at least 5 wt%, or at least 10 wt%, or at least 15 wt%, or optionally greater than the wax content of said base oil feed; a nitrogen content of 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; a sulfur content of 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 in the range of 100 to 8000 ppm, or 100 to 6000 ppm, or 100 to 4000 ppm, or 100 to 2000 ppm, or 100 to 1000 ppm, or 100 to 500 ppm, or 100 to 200 ppm; and / or 1050+°F content within the range of 5-50 wt%, or 5-40 wt%, or 8-40 wt%, or optionally above the 1050+°F content of said base oil feed.

3. 3. The process of any one of claims 1 to 2, wherein the base oil feed meets one or more of the following conditions: an API gravity in the range of 15 to 40, or 15 to 30, or 15 to 25, or at least 15, or at least 17, optionally less than that of said atmospheric resid feed; a VI in the range of 30 to 90, or 40 to 90, or 50 to 90, or 50 to 80, optionally less than the VI of said atmospheric resid feed; a viscosity at 100°C in the range of 3 to 30 cSt, or 3 to 25 cSt, or 3 to 20 cSt, or at least 3 cSt, or at least 4 cSt; a viscosity at 70°C in the range of 5 to 25 cSt, or 5 to 20 cSt, or 5 to 15 cSt, or at least 5 cSt, or at least 6 cSt; fever C ７ an asphaltene content in the range of 0.01 to 0.3 wt%, or 0.01 to 0.2 wt%, or 0.02 to 0.15 wt%, or less than 0.3 wt%, or less than 0.2 wt%; a wax content in the range of 5 to 40 wt%, or 5 to 30 wt%, or 10 to 25 wt%, or at least 5 wt%, or at least 10 wt%, or at least 15 wt%, or optionally greater than the wax content of said base oil feed; a nitrogen content of 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; a sulfur content of 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 in the range of 100 to 8000 ppm, or 100 to 6000 ppm, or 100 to 4000 ppm, or 100 to 2000 ppm, or 100 to 1000 ppm, or 100 to 500 ppm, or 100 to 200 ppm; and / or 1050+°F content within the range of 5-50 wt%, or 5-40 wt%, or 8-40 wt%, or optionally above the 1050+°F content of said base oil feed.

4. 4. The process of any one of claims 1 to 3, wherein the base feedstream comprises 10 to 60 wt% atmospheric residua feed and 40 to 90 wt% base stock, or 10 to 40 wt% atmospheric residua feed and 60 to 90 wt% base stock, or 10 to 30 wt% atmospheric residua feed and 70 to 90 wt% base stock, or 30 to 60 wt% atmospheric residua feed and 40 to 70 wt% base stock, or 40 to 60 wt% atmospheric residua feed and 40 to 60 wt% base stock.

5. 5. The process of any one of claims 1 to 4, wherein the base oil feedstream does not contain any added whole crude feed, or wherein the base oil feedstream does not contain any vacuum resid feed, or wherein the base oil feedstream does not contain any deasphalted oil, or wherein the base oil feedstream comprises only atmospheric resid feed and base oil feed.

6. 6. The process of any one of claims 1 to 5, wherein the process does not include recycling a liquid feed as part of the base oil feedstream, or recycling a liquid feed as one or both of the atmospheric resid feed and the base oil feed.

7. 7. The process of any one of claims 1 to 6, wherein the base oil stock comprises, is, consists essentially of, or consists of vacuum gas oil.

8. 8. The process of claim 7, wherein the vacuum gas oil is a heavy vacuum gas oil obtained by cutting a vacuum gas oil into a light fraction and a heavy fraction, the heavy fraction having a cut temperature range of about 950-1050°F.

9. The process of any one of claims 1 to 8, wherein the dewaxed product and / or the hydrofinished dewaxed product are obtained as a light base oil product and a heavy base oil product.

10. 10. The process of claim 9, wherein the light base oil product has an apparent viscosity at 100°C in the range of 4 to 8 cSt or 5 to 7 cSt, and / or the heavy base oil product has an apparent viscosity at 100°C in the range of 10 to 14 cSt or 11 to 13 cSt.

11. 11. The process of any one of claims 9-10, wherein the yield of said heavy base oil product relative to said light base oil product is increased by at least about 2 L vol % or at least about 5 L vol % compared to the same process without said atmospheric resid feed in the base oil feedstream.

12. 12. The process of any one of claims 9 to 11, wherein the overall yield of the waxy base oil is increased by at least about 2 liter volume % or at least about 5 liter volume % compared to the same process without the atmospheric resid feed in the base oil feedstream.

13. 11. The process of any one of claims 1 to 10, wherein the dewaxed product is at least further separated into a lighter product having an apparent viscosity at 100°C of 6 cSt, or at least further separated into a heavier product having an apparent viscosity at 100°C of 12 cSt, or a combination thereof.

14. 1. A method for modifying a base oil process, the base oil process comprising subjecting a base oil feedstream to hydrocracking and dewaxing steps to form a dewaxed product comprising light and heavy products, the method comprising: combining an atmospheric resid feed with a base oil feed to form said base oil feedstream; and subjecting said base oil feedstream comprising said atmospheric resid feed to said hydrocracking and dewaxing steps of said base oil process; Including, The modified base oil process comprises: combining an atmospheric resid feed and a base oil feed to form a base oil feedstream; contacting the base oil feedstream with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracked product; separating the hydrocracking product into at least a gas fraction and a liquid fraction; contacting the liquid fraction with a dewaxing catalyst under hydroisomerization conditions to obtain a dewaxed product; and optionally contacting the dewaxed product with a hydrofinishing catalyst under hydrofinishing conditions to obtain a hydrofinished dewaxed product; The method comprising:

15. 1. A process for preparing a base oil, said process comprising: contacting a base oil feedstock having a viscosity index of about 100 or greater with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracked product, said base oil feedstock comprising a vacuum gas oil having a front end cut temperature of about 700°F or greater and a back end cut temperature of about 900°F or less; separating the hydrocracking product into a gas fraction and a liquid fraction; contacting the liquid fraction with a dewaxing catalyst under hydroisomerization conditions to obtain a dewaxed product; and optionally contacting the dewaxed product with a hydrofinishing catalyst under hydrofinishing conditions to obtain a hydrofinished dewaxed product; Including, The foregoing process wherein after dewaxing, the dewaxed product and / or the hydrofinished dewaxed product has a viscosity index of 120 or greater.

16. 16. The process of claim 15, wherein after dewaxing, the dewaxed product and / or the hydrofinished dewaxed product has a viscosity index of 130 or greater, or 135 or greater, or 140 or greater.

17. 16. The process of claim 15, wherein the dewaxed product and / or the hydrofinished dewaxed product comprises a Group III or Group III+ base oil product.

18. 16. The process of claim 15, wherein the hydrocracking product has a viscosity index of at least about 135, or at least about 140, or at least about 145, or at least about 150.

19. 19. The process of any one of claims 15 to 18, wherein the yield of said waxy product when said vacuum gas oil has a front end cut of about 700°F or greater and a back end cut of about 900°F or less and a viscosity at 100°C of 4 cSt is increased by at least about 3 vol % compared to the same process not including said vacuum gas oil having a front end cut of about 700°F or greater and a back end cut of about 900°F or less as said base oil feed.

20. 1. A process for preparing a base oil from a base oil stock or a fraction thereof, said process comprising: Obtaining an atmospheric resid fraction from a base oil feedstock or a fraction thereof; separating said base oil feed or fractions thereof and / or said base oil atmospheric resid fraction into vacuum gas oil cut temperature fractions having a front end cut temperature of at least about 700°F and a back end cut temperature of at most about 900°F to form a medium vacuum gas oil (MVGO) fraction and a heavy vacuum gas oil (HHVGO) fraction; 10. The process of claim 1, wherein the HHVGO fraction is used as the atmospheric resid feedstock; and / or 15. The process of claim 14, wherein the MVGO fraction is used as the base oil feedstock. The process comprising:

21. 21. The process of claim 20, wherein the base oil feed comprises a tight oil or fraction thereof.

22. 22. The process of claim 21, wherein the vacuum gas oil cut temperature fraction is obtained from the atmospheric resid fraction of the tight oil.

Images