Co-processing of used lubricating oil to produce group ii / iii base stocks

Abstract

Embodiments may include methods of processing a used lubricating oil, and methods relating to producing high quality Group II base stock, Group II+ base stock, and Group III base stock from co-processing vacuum gas oil (VGO) with pre-processed used lubricating oil.

Description

CO PROCESSING OF USED LUBRICATING OIL TO PRODUCE GROUP II / III BASE STOCKSFIELD

[0001] This disclosure relates to base stocks, and more particularly, embodiments relate to base stocks made from used lubricating oils, blends of base stocks, formulated lubricant compositions containing the base stocks, and methods of making base stocks from used oils and methods of using base stocks.BACKGROUND

[0002] Base stocks are the maj or constituent in finished lubricants and contribute significantly to their properties. For example, engine oils are finished crankcase lubricants intended for use in automobile engines and diesel engines and contain two general components, namely, a base stock (one base stock or a blend of base stocks) and additives. In general, a few lubricating base stocks are used to manufacture a variety of engine oils by varying the mixtures of individual lubricating base stocks and individual additives. Base stocks are also used for other purposes and industries such as processing oils for manufacturing and industrial oils in the marine and paper industries.

[0003] According to the American Petroleum Institute (API) classifications, base stocks are categorized in five groups based on their saturated hydrocarbon content, sulfur level, and viscosity index (Table 1). Lubricant base stocks are typically produced on a large scale from petroleum sources. Group I, II, and III base stocks are all derived from crude oil via extensive processing, such as solvent extraction, solvent or catalytic dewaxing, and hydroisomerization. Group III base stocks can also be produced from synthetic hydrocarbon liquids obtained from natural gas, coal or other fossil resources, Group IV base stocks are polyalphaolefins (PAOs), and are produced by oligomerization of alpha olefins, such as 1 -decene. Group V base stocks include all base stocks that do not belong to Groups I-IV, such as naphthenics, polyalkylene glycols (PAG), and esters.Table 1

[0004] Base stocks are the key building blocks of lubricants and greases. A base stock is typically defined as a single lubricant component produced by a single manufacturer. The terms base stocks and base oils are often used interchangeably, but there are differences. A base stock is a single product, usually defined by its viscosity grade. A mixture of one or more base stocks(4600-19301) in a finished lubricant is a base oil. A base oil is always defined in the context in the formulated lubricant. Base oil properties can vary’ depending on their API group. Base stocks are generally- produced from the higher boiling fractions recovered from a vacuum distillation operation. Base stocks are prepared from either petroleum-derived or from syncrude-derived feed stocks or from synthesis of lower molecular weight molecules. Base stocks are blended to form a base oil to which additives are added to form the finished lubricant. Additives are chemicals which are added to base stock to improve certain properties in the finished lubricant so that it meets the minimum performance standards for the grade of the finished lubricant. For example, additives added to engine oils are used to improve oxidation stability- of the lubricant, increase its viscosity-, raise the viscosity index, and control deposits.

[0005] Lubricating oils are utilized in machinery for various purposes such as to lubricate surfaces, cool components, provide anti-corrosion and other modifiers to surfaces, and catch contaminants from combustion. Lubricating oils are utilized in a variety- of applications including, but not limited to, vehicle engines, industrial gearboxes and pumps, compressors, and hydraulic units. When the lubricating oil is circulated throughout the machinery, the lubricating oil becomes contaminated yvith metal shavings and debris from the machinery- as well as chemical impurities such as water, fuel, and combustion products.

[0006] Lubricating oils are changed when the oil no longer meets the specification requirements or at regular intervals. The lubricating oil becomes “used up” when the additive package in the lubricating oil is depleted and the oil becomes contaminated. However, the base oils which make up the bulk volume of the lubricating oils are not used up under normal engine conditions and thus is recycled to form neyv base oils. Re-refiners may utilize the used lubricating oil in a reclamation process to recover the base stock fractions in the used lubricating oil. The reclamation process typically includes multiple cleaning and stripping steps to remove physical and chemical contaminants from the used lubricating oil followed by liquid-liquid extraction processes to recover a Group I base stock and loyv pressure hydrotreating to recover group II base stocks.SUMMARY

[0007] The invention includes methods for producing base stocks from used oils such as pre- processed used lubricating oils. According to an embodiment, the invention includes a method for producing base stock from pre-processed used lubricating oil comprising: introducing a feed stream comprising pre-processed used lubricating oil and vacuum gas oil into a sour hydrocracking section; contacting the feed stream with a first hydrotreating catalyst followed bycontacting the hydrotreated feed stream with a first hydrocracking catalyst and hydrogen in the sour hydrocracking section at sour hydrocracking conditions effective to hydrocrack at least a(4600-19301) portion of the feed stream to form a hydrocracked effluent; separating the hydrocracked effluent to form a wide or narrow cut hydrocrakate stream comprising lubricant boiling range hydrocarbons; introducing the wide or narrow cut hydrocrackate stream into a sweet hydrocracking section; contacting the wide or narrow cut hydrocrackate stream with a second hydrocracking catalyst and hydrogen in the sweet hydrocracking section at sweet hydrocracking conditions effective to hydrocrack at least a portion of the hydrocrackate stream to form a second hydrocrackate stream comprising additional lubricant boiling range hydrocarbons; introducing the second hydrocrackate stream into a catalytic dewaxing section; contacting the second hydrocrackate stream with a dewaxing catalyst and hydrogen in the catalytic dewaxing section at catalytic dewaxing conditions effective to dewax at least a portion of the second hydrocrackate stream to from a dewaxed effluent; introducing the dewaxed effluent into a hydrofinishing section; contacting the dewaxed effluent with a hydrofinishing catalyst and hydrogen in the hydrofinishing section at hydrofinishing conditions to hydrofinish at least a portion of the dewaxed effluent to form a hydrofinished effluent; and introducing the hydrofinished effluent into a separation section and separating at least a portion of the lubricant boiling range hydrocarbons to form a base stock fraction.

[0008] According to a further embodiment, the invention includes a method for producing base stock from pre-processed used oils comprising: introducing a feed stream comprising pre- processed used lubricating oil and vacuum gas oil into a sour hydrocracking section, wherein the feed stream comprises about 5 vol.% to about 15 vol.% pre-processed used lubricating oil. and contacting the feed stream with a first hydrotreating catalyst followed by contacting the hydrotreated feed stream with a first hydrocracking catalyst and hydrogen in the sour hydrocracking section at sour hydrocracking conditions effective to hydrocrack at least a portion of the feed stream to form a hydrocracked effluent stream comprising lubricant boiling range hydrocarbons; introducing the hydrocracked effluent stream into a light ends separation unit and separating a light ends fraction from the hydrocracked effluent stream and thereafter introducing the hydrocracked effluent stream into a sweet hydrocracking section and contacting the hydrocracked effluent stream with a second hydrocracking catalyst and hydrogen in the sweet hydrocracking section at sweet hydrocracking conditions effective to hydrocrack at least a portion of the hydrocrackate stream to form a second hydrocrackate stream comprising additional lubricant boiling range hydrocarbons; introducing the second hydrocrackate stream into a dewaxing section and contacting the second hydrocrackate stream with a dewaxing catalyst and hydrogen in the dewaxing section at catalytic dewaxing conditions effective to dewax at least a portion of the second hydrocrackate stream to from a dewaxed effluent; introducing the dewaxed(4600-19301) effluent into a hydrofinishing section and contacting the dewaxed effluent with a hydrofinishing catalyst and hydrogen in the hydrofinishing section at hydrofinishing conditions to hydrofinishing at least a portion of the dewaxed effluent to form a hydrofinished effluent; and separating at least a portion of the lubricant boiling range hydrocarbons from the hydrofinished effluent to form a base stock fraction.

[0009] These and other features and attributes of the disclosed methods for producing base stocks from pre-processed used lubricating oils, base stocks made from pre-processed used lubricating oils, blends of base stocks, formulated lubricant compositions containing the base stocks, and uses of base stocks of the present disclosure and their advantageous applications and / or uses will be apparent from the detailed description which follows.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] To assist those of ordinary skill in the relevant art in making and using the subj ect matter hereof, reference is made to the appended drawings, wherein:

[0011] FIG. 1 is a schematic illustration of a process for processing used lubricating oil, in accordance with certain embodiments of the present disclosure.

[0012] FIG. 2A is a graph of sour stage hydrotreating / hydrocracking conversion at 370 °C utilizing processing used lubricating oil, in accordance with certain embodiments of the present disclosure.

[0013] FIG. 2B is a graph of sour stage hydrotreating / hydrocracking conversion at 370 °C utilizing processing used lubricating oil, in accordance with certain embodiments of the present disclosure.DETAILED DESCRIPTION

[0014] Disclosed herein are methods of processing a used lubricating oil, and more particularly, embodiments relate to methods to form high quality Group II base stockand Group III base stock from co-processing vacuum gas oil (VGO) with used lubricating oil. The embodiments disclosed herein have several advantages over previously disclosed methods of processing a used lubricating oil, only some of which are allude to hereinThe Group II base stock, , and Group III produced according to the embodiments disclosed herein have viscosity index (VI). cold crank simulator (CCS), and other relevant physical properties within range of conventionally produced Group II base stock, and Group III base stock, thereby allowing the Group II base stock, and Group III base stock produced from the used lubricating oil to be integrated into existing blending schemes.Feedstocks

[0015] In various embodiments, the used lubricating oil employed in the present process may be collected from various sources including industrial, commercial, and / or residential sources and(4600-19301) may include mixtures of used lubricating oils from these sources. In embodiments, the used lubricating oil has been used in an engine, transmission, or other lubricating application. The used lubricating oil may include, without limitation, oils such as transmission oil, gear oil, engine oil, crankcase oil, compressor oil, pump oil, hydraulic oil, or any combination thereof. The used lubricating oil in some examples includes a mixture of petroleum mineral oils derived from the processing of petroleum crude and / or oils, used lubricating oil containing base stocks derived from fischer tropsch waxes, used lubricating oil containing base stocks derived from polyolefin processing, used mineral oils, and used synthetic base oils. In embodiments, the used lubricating oil includes additive packages including but not limited to antiwear additives, detergents, dispersants, viscosity modifiers, corrosion inhibitors, rust inhibitors, metal deactivators, extreme pressure additives, anti-seizure agents, wax modifiers, other viscosity modifiers, fluid-loss additives, seal compatibility agents, lubricity agents, anti-staining agents, chromophoric agents, anti-foam agents, antioxidants, anti-rust additives, anti-wear additives, pour point depressant, demulsifiers, emulsifiers, densifiers, wetting agents, gelling agents, tackiness agents, colorants, and others. In embodiments the used lubricating oil includes water and insoluble particulates such as carbon, metal shavings, and combustion deposits.

[0016] In embodiments, the used lubricating oil is subjected to a series of pre-processing steps whereby the used lubricating oil is cleaned of at least a portion of the contaminants such as additives, water, and insoluble particles. For example, water may be removed in a dehydration unit whereby water may be stripped, decanted, or otherwise removed from the bulk used lubricating oil. In embodiments, a filtration unit is utilized to filter solid particulates from the used lubricating oil. In embodiments, the used lubricating oil may be subjected to vacuum distillation, chemical addition, or other separation steps.

[0017] In embodiments, pre-processed used lubricating oil is utilized as a feedstock in the disclosed methods of producing base stocks. The feedstock for the process can have any viscosity. In various embodiments, the pre-processed used lubricating oil has a kinematic viscosity' at 100° C. (KV100) of at least 3 centistokes (cSt). In various embodiments, the feedstock has a KVIOO at a point in a range of 3 cSt to 8 cSt. Alternatively, the feedstock has a K.VI00 at a point in a range of 3 cSt to 5.5 cSt, at a point in a range of 5.5 cSt to 8 cSt. at a point in a range of 4 cSt to 6 cSt or any ranges therebetween. Although the feedstock can have any viscosity index (VI), in various embodiments the used lubricating oil has a VI of at least 90, preferably in a range of 100-120. In some embodiments, the feedstock has a VI at a point in a range of from 90 tol30. Alternatively, the feedstock has a VI at a point in a range of from 90 to 115, at a point in a range of from 115 to 130, or any ranges therebetween. In embodiments, the pre-processed used lubricating oil has an(4600-19301) initial boiling point (T5) at a point in a range of 330 °C to 380 °C and a final boiling point (T95) in a range of 450 °C to 560 °C. In further embodiments the pre-processed used lubricating oil contains low levels of contaminants, including spent additives and wear materials, such as about 0.00 wt.%, 0.01 to 5.0 wt. %, 0.05 to 2.0 wt. % contaminant loading, or any ranges there-between.

[0018] In some embodiments, the pre-processed used lubricating oil contains greater than 500 wppm sulfur as determined by ASTM 2622. When the pre-processed used lubricating oil contains greater than 500 wppm sulfur, the oil is considered a ‘"sour’7feed. In embodiments, the pre- processed used lubricating oil contains sulfur in an amount of 500 wppm to 5,000 wppm sulfur. In example embodiments including a hydrotreatment process and / or a sour hydrocracking process, the feed can have a sulfur content of 500 wppm to 1000 wppm, or 1000 wppm to 2500 wppm, 2500 wppm to 5000 wppm, or any ranges therebetween. Additionally or alternately, the nitrogen content may be in a range of 0 wppm to 1000 wppm, 50 wppm to 500, 500 to 1000 wppm, or any ranges therebetween. In some embodiments, the feed can correspond to a “sweet” feed, so that the sulfur content of the feed is about 10 wppm to about 200 wppm and / or the nitrogen content is about 1 wppm to about 20 wppm.

[0019] In embodiments, the pre-processed used lubricating oil contains halides in an amount of 0 wppm to 100 wppm, such as from 0 wppm to 25 wppm, 25 wppm to 50 wppm, 50 wppm to 100 wppm, or any ranges therebetween. In further embodiments, the pre-processed used lubricating oil contains a total content of metal contaminants by D5185 such as phosphorus, calcium, zinc and silicon is typically between from 0 wppm to 200 wppm, such as from 0 wppm to 25 wppm, 25 wppm to 100 wppm, 100 wppm to 200 wppm, or any ranges therebetween.

[0020] In embodiments, the pre-processed used lubricating oil is co-processed with vacuum gas oil (VGO). As used herein, “vacuum gasoil,” “VGO,” “vacuum gasoil-range,” and grammatical variations thereof, refer to a hydrocarbon composition characterized by a Ts distillation temperature in a range of about 644° F. (340° C.) to about 716° F. (380° C.) and a T95 distillation temperature in a range of about 840° F. (460° C.) to about 1058° F. (580° C.) as measured according to ASTM D2887. Vacuum gas oil is ty pically produced from vacuum distillation of atmospheric column bottoms from an atmospheric distillation unit. It should be noted that a polyalphaolefin or unsaturated PAO of the present disclosure can be introduced into a stream during the re-refining process, for example before or after distillation / hydrogenation. As used herein, “polyalpha-olefin(s)” (“PAO(s)”) includes any oligomer(s) and polymer(s) of one or more alpha-olefin monomer(s). PAOs are oligomeric or polymeric molecules produced from the polymerization reactions of alpha-olefin monomer molecules in the presence of a catalyst system, optionally further hydrogenated to remove residual carbon-carbon double bonds therein. Thus, the(4600-19301)PAO can be a dimer, a trimer, a tetramer, or any other oligomer or polymer comprising two or more structure units derived from one or more alpha-olefin monomer(s).Process for Producing Base Stocks

[0021] FIG. 1 is a block flow diagram of a process 100 to produce base stocks in accordance with some embodiments of the present disclosure. As discussed above, pre-processed used lubricating oil can come from many sources. As shown in FIG. 1 pre-processed used lubricating oil 102 is introduced into optional demetallization section 104. In demetallization section 104, where the pre-processed used lubricating oil is mixed with hydrogen and contacted with a demetallization catalyst at conditions suitable to remove at least a portion of metals from the oil. Without being limited by theory, it is believed that the hydrogen facilitates the reaction by reducing the metal components present in the oil to the corresponding metallic form and thereafter the reduced metals are then adsorbed onto the demetallization catalyst and removed from the oil. In embodiments, the demetallization catalysts include active metals on a support. Some examples of active metals include molybdenum, nickel, cobalt, iron, platinum, ruthenium, and combinations thereof. In embodiments, the supports include alumina, zeolites, silica, carbon-based materials such as activated carbon and carbon nanotubes, and combinations thereof.

[0022] The demetallization section 104 is operated at hydrodemetallization conditions. In embodiments, the demetallization section 104 is operated at a temperature at a point in a range of 250 °C to 400 °C. Alternatively, the demetallization section 104 is operated at a temperature at a point in a range of 250 °C to 275 °C. at a point in a range of 275 °C to 300 °C. at a point in a range of 300 °C to 350 °C, at a point in a range of 350 °C to 400 °C, or any ranges therebetween. In embodiments, the demetallization section 104 is operated at hydrogen partial pressure at a point in a range of 500 psig (3.44 MPa) to 3000 psig (20.68 MPa). Alternatively, the hydrotreatment unit is operated at a hydrogen partial pressure at a point in a range of 500 psig (3.44 MPa) to 1000 psig (6.89 MPa), at a point in a range of 1000 psig (6.89 MPa) to 2000 psig (13.78 MPa), at a point in a range of 2000 psig (13.78 MPa) to 3000 psig (20.68 MPa), or any ranges therebetween. In embodiments, the demetallization section 104 is operated at a total treat gas ratio, i.e. the treat gas at reactor inlet and all inter-bed gas quenches, at a point in a range of 1000 scf / B to 5000 scf / B. Alternatively, the demetallization section 104 is operated at a total treat gas ratio at a point in a range of 1000 scf / B to 2000 scf / B, at a point in a range of 2000 scf / B to 2500 scf / B, at a point in a range of 2500 scf / B to 5000 scf / B, or any ranges therebetween. In embodiments, the demetallization section 104 is operated at a Liquid Hourly Space Velocity (LHSV) at a point in a range of 0. 1-5.0 h1in the demetallization section 104. Alternatively, at a LHSV at point in a range(4600-19301) of 0. 1-1.0 h '. at a point in a range of 1.0-2.5 li '. at a point in a range of 2.5-5.0 h '. or any ranges therebetween in the demetallization section 104.

[0023] In embodiments, the used lubricating oil is demetallized to any suitable degree such that the demetallized used lubricating oil contains a total metal content of less than 0.01 wt.% metal such as in a range of 0.00 wt.% to 0.01 wt.%. Alternatively, from at a point in a range of 0.00 wt.% to 0.001 wt.%, at a point in a range of from 0.001 wt.% to 0.005 wt.%, at a point in a range of 0.005 wt.% to 0.01 wt.%. or any ranges therebetween.

[0024] From demetallization section 104, demetallized used lubricating oil 106 is introduced into sour hydrocracking section 110 with wide or narrow cut vacuum gas oil co-feed 108. In embodiments, hydrocracking section 110 includes an optional demetallization, hydrotreatment bed and a hydrocracking bed where the hydrotreatment bed pre-treats the feed to the hydrocracking bed by reducing heteroatoms such as N in the feed. In embodiments, the feed to the hydrocracking section 110 includes the demetallized pre-processed used lubricating oil in an amount of 1 vol.% to 50 vol.%. Alternatively, at a point in a range of from 1 vol.% to 5 vol.%, at a point in a range of 5 vol.% to 15 vol.%, at a point in a range of 15 vol.% to 25 vol.%, at a point in a range of 25 vol.% to 35 vol.%. at a point in a range of 35 vol.% to 50 vol.%. or any ranges therebetween. The demetallized used lubricating oil can include sulfur in an amount of greater than 500 wppm such that the hydrotreatment section corresponds to sour section hydrocracking. Hydro treatment and hydroctracking reduces the sulfur, nitrogen, and aromatic content of the demetallized used lubricating oil.

[0025] Sour hydrocracking section 110 includes at least one sour hydrocracking section which includes a hydrocracking catalyst. In embodiments, hydrocracking catalysts include sulfided base metals on acidic supports, such as amorphous silica alumina, cracking zeolites such as USY, or acidified alumina. In further embodiments, these acidic supports are mixed or bound with metal oxides such as alumina, titania or silica. In embodiments, hydrocracking catalysts include a zeolitic base selected from any of zeolite Beta, zeolite X, zeolite Y, faujasite, ultrastable Y (USY), dealuminized Y (Deal Y), Mordenite, ZSM-3, ZSM-4, ZSM-18, ZSM-20, ZSM-48, or any combinations thereof, which zeolitic base is loaded with one or more active metals (e.g., either (i) a Group 8-10 noble metal such as platinum and / or palladium or (ii) a Group 8-10 non-noble metal such nickel, cobalt, iron, and combinations thereof, and a Group 6 metal such as molybdenum and / or tungsten).

[0026] Sour hydrocracking section 110 is operated at sour hydrocracking conditions such as a temperature at a point in a range of 300 °C to 450 °C. Alternatively, a temperature at a point in a range of 300 °C to 350 °C, a temperature at a point in a range of 350 °C to 400 °C, a temperature(4600-19301) at a point in a range of 400 °C to 450 °C, or a temperature at any ranges therebetween. In embodiments, sour hydrocracking section 110 is operated at hydrogen partial pressure at a point in a range of 500 psig (3.44 MPa) to 3000 psig (20.68 MPa). Alternatively, the sour hydrocracking section unit is operated at a hydrogen partial pressure at a point in a range of 500 psig (3.44 MPa) to 1000 psig (6.89 MPa), at a point in a range of 1000 psig (6.89 MPa) to 2000 psig (13.78 MPa), at a point in a range of 2000 psig (13.78 MPa) to 3000 psig (20.68 MPa), or any ranges therebetween. In embodiments, sour hydrocracking section 110 is operated at a total treat gas ratio, i.e. the treat gas at reactor inlet and all inter-bed gas quenches, at a point in a range of 2000 scf / B to 10,000 scf / B. Alternatively, sour hydrocracking section 110 is operated at a total treat gas ratio at a point in a range of 2000 scf / B to 3000 scf / B, at a point in a range of 3000 scf / B to 5000 scf / B, at a point in a range of 5000 scf / B to 10,000 scf / B, or any ranges therebetween. In embodiments, sour hydrocracking section 110 is operated at liquid hourly space velocities (LHSV) at a point in a range of from 0.2 h1to 10 h '. Alternatively, LHSV at a point in a range of from 0.2 h1to 1 h '. LHSV at a point in a range of from 1 h1to 3 h '. LHSV at a point in a range of from 3 h1to 6 h '. LHSV at a point in a range of from 6 h1to 10 h or any ranges therebetween.

[0027] In embodiments, hydrocracked effluent stream 112 corresponds to a sweet stream where the stream contains sulfur in an amount of 250 wppm or less, or 200 wppm or less, or 150 wppm or less, or 100 wppm or less, or 50 wppm or less, or 25 wppm or less, or 10 wppm or less. In particular, the sulfur content of the hydrocracked effluent include 1 wppm to 250 wppm, or 1 wppm to 50 wppm, or 1 wppm to 10 wppm. Additionally, or alternatively, the conditions in the initial hydrocracked section are sufficient to reduce the nitrogen content to 100 wppm or less, or 50 wppm or less, or 25 wppm or less, or 10 wppm or less. In particular, the nitrogen content includes 1 wppm to 100 wppm, or 1 wppm to 25 w ppm, or 1 w ppm to 10 wppm. In embodiments, a portion of the feed to sour hydrocracking section 110 is cracked to light end hydrocarbons.

[0028] The sour hydrocracking is carried out in the presence of hydrogen. A hydrogen stream is, therefore, fed or injected into a vessel or reaction zone or hydroprocessing zone in which the hydrocracking catalyst is located. Hydrogen, which is contained in a hydrogen “treat gas,’' is provided to the reaction zone. Treat gas includes either pure hydrogen or a hydrogen-containing gas, which is a gas stream containing hydrogen in an amount that is sufficient for the intended reaction(s), optionally including one or more other gasses (e.g., and light hydrocarbons such as methane), and which will not adversely interfere with or affect either the reactions or the products. The effluent from the demetallization section is contacted with the hydrogen in the presence of the hydrotreating catalyst to reduce amount the sulfur, nitrogen, and / or aromatic.(4600-19301)

[0029] As used herein, lubricant boiling range is defined as 650° F. (343° C.) to 1050° F. (566° C.). Optionally, when forming a lubricant boiling portion by fractionation after one or more sections of hydroprocessing (e.g., hydrotreating, hydrocracking, catalytic dewaxing, hydrofinishing), a lubricant boiling range portion can optionally correspond to a bottoms fraction, so that higher boiling range compounds may also be included in the lubricant boiling range portion. Compounds (C4-) with a boiling point below the naphtha boiling range is referred to as light ends.

[0030] From sour hydrocracking section 110, hydrocracked effluent stream 112 is introduced into light end separation unit 114. Light end separation unit 114 is configured to separate the hydrocracked oil from light ends such as hydrocarbon light ends and contaminant gasses such as hydrogen sulfide, ammonia, and water generated in sour hydrocracking section 110. Light ends are withdrawn from light end separation unit 114 as light ends stream 142. In embodiments, light end separation unit 114 includes equipment such as strippers, distillation columns, fractionators, or any other equipment suitable for separating the hydrocracked oil from the light ends into fuels fractions and heavy hydrocrackate, also referred to as unconverted oil (UCO). In embodiments, either the wide or narrow cut hydrocrackate stream 116 includes primarily the lubricant boiling range hydrocarbons.

[0031] From light ends and fuel separation unit 114, a wide or narrow cut hydrocrackate stream 116 is introduced into sweet hydrocracking section 122. As hydrocracked effluent stream 112 corresponds to a sweet stream, wide or narrow cut hydrocrackate stream 116 also corresponds to a sweet steam having less than 250 wppm of sulfur. Sweet hydrocracking section 122 is configured to hydrocrack the narrow^ or wide cut hydrocrackate under sweet process conditions which are similar to process conditions used for a sour hydrocracking process, or the conditions can be different. In an embodiment, the conditions in a sweet hydrocracking section can have less severe conditions than a hydrocracking process in a sour section. In embodiments, sweet hydrocracking section 122 includes a hydrocracking catalyst such as those previously described.

[0032] In embodiments, sweet hydrocracking section 122 is operated at sweet hydrocracking conditions such as a temperature at a point in a range of 300 °C to 450 °C. Alternatively, a temperature at a point in a range of 300 °C to 350 °C, a temperature at a point in a range of 350 °C to 400 °C, a temperature at a point in a range of 400 °C to 450 °C, or a temperature at any ranges therebetween. Further sweet section hydrocracking conditions include hydrogen partial pressure at a point in a range of 500 psig (3.44 MPa) to 3000 psig (20.68 MPa). Alternatively, the sweet hydrocracking section is operated at a hydrogen partial pressure at a point in a range of 500 psig (3.44 MPa) to 1000 psig (6.89 MPa), at a point in a range of 1000 psig (6.89 MPa) to 2000(4600-19301) psig (13.78 MPa), at a point in a range of 2000 psig (13.78 MPa) to 3000 psig (20.68 MPa), or any ranges therebetween. In embodiments, sweet hydrocracking conditions further liquid hourly- space velocities (LHSV) at a point in a range of from 0.2 h1to 10 h Alternatively, LHSV at a point in a range of from 0.2 h1to 1 h '. LHSV at a point in a range of from 1 h1to 3 h LHSV at a point in a range of from 3 h1to 6 h '. LHSV at a point in a range of from 6 h1to 10 h or any ranges therebetween. In embodiments, sweet section hydrocracking conditions include a total treat gas ratio, i.e. the treat gas at reactor inlet and all inter-bed gas quenches, at a point in a range of 2000 scf / B to 10,000 scf / B. Alternatively, sweet section hydrocracking conditions include a total treat gas ratio at a point in a range of 2000 scf / B to 3000 scf / B, at a point in a range of 3000 scf / B to 5000 scf / B, at a point in a range of 5000 scf / B to 10,000 scf / B, or any ranges therebetween.

[0033] Hydrocrackate stream 124 is withdrawn from sweet hydrocracking section 122 and introduced into dewaxing section 126. In catalytic dewaxing the lubricant boiling range hydrocarbons and naphtha / distillate fuel boiling range hydrocarbons, if present, from hydrocrackate stream 124 are reacted with hydrogen in the presence of a suitable dewaxing catalyst at conditions effective to lower the pour point of the lubricant boiling range hydrocarbons. Alternatively, the dewaxing section may have a secondary aromatic saturation catalyst bed prior or post the dewaxing catalyst beds.

[0034] In embodiments, dewaxing section 126 includes a dewaxing catalyst that performs dewaxing primarily by isomerizing a hydrocarbon feedstock. In embodiments, the catalysts are zeolites with a unidimensional pore structure. In some embodiments, the catalyst includes 10- member ring pore zeolites, such as EU-1 , ZSM-35 (or ferrierite), ZSM-1 1 , ZSM-57, NU-87, S APO-11, and ZSM-22. In embodiments, the dewaxing catalyst includes Theta- 1, NU-10, EU- 13, KZ-1, and NU-23, EU-2, EU-11, ZBM-30, ZSM-48, or ZSM-23. In embodiments, the dewaxing catalyst includes a metal hydrogenation component. The metal hydrogenation component is typically a Group VI and / or a Group VIII metal. In embodiments, the metal hydrogenation component is Pt, Pd, or a mixture thereof. In an alternative embodiment, the metal hydrogenation component includes a combination of a non-noble Group VIII metal with a Group VI metal. Suitable combinations can include Ni, Co, or Fe with Mo or W and / or Ni with Mo or W.

[0035] In embodiments, the hydrofinishing section 130 includes a hydrogenation catalyst that includes Pt, Pd, or a combination thereof on a support such as alumina or titania. In embodiments the hydrogenation catalyst includes hydrotreating catalysts with Pt or Pd supported on alumina, amorphous alumina / silica, and / or zeolite. In embodiments, the hydrogenation catalyst can include from 0. 1 wt. % to 2.0 wt. % of hydrogenation metal relative to the weight of the support. Due to(4600-19301) the low acidity support, this type of catalyst causes little or no cracking of feed while being effective for reduction of single ring and multi-ring aromatics.

[0036]

[0037] In embodiments, dewaxing section 126 is operated at catalytic dewaxing conditions including a temperature at a point in a range of from 300 °C - 400 °C. Alternatively, a temperature at a point in a range of from 200 °C to 250 °C, a temperature a point in a range of from 250 °C to 350 °C, a temperature a point in a range of from 350 °C to 450 °C, or a temperature any ranges therebetween. Further catalytic dewaxing conditions include hydrogen partial pressure at a point in a range of from 500 psig (3.4 MPa) to 3000 psig (20.7 MPa). Alternatively, catalytic dewaxing conditions include a hydrogen partial pressure at a point in a range of from 500 psig (3.4 MPa) to 1000 psig (6.9 MPa). 1000 psig (6.9 MPa) to 2000 psig (13.8 MPa), 2000 psig (13.8 MPa) to 3000 psig (20.7 MPa), or any ranges therebetween.

[0038] Further catalytic dewaxing conditions include a LHSV at a point in a range of 0.5 to 5.0 v / v / hr. Alternatively, a LHSV at a point in a range of 0.5 to 1 v / v / hr, a LHSV at a point in a range of 1 to 1.5 v / v / hr, a LHSV at a point in a range of 1.5 to 3.0 v / v / hr., a LHSV at a point in a range of 3.0 to 5.0 v / v / hr., or any ranges therebetween. Further catalytic dewaxing conditions include a hydrogen circulation rate of from 2000 to 5000 scf / B.

[0039] Dewaxed effluent stream 128 includes lubricant boiling range hydrocarbons and naphtha / distillate fuel boiling range hydrocarbons generated from dewaxing, if present. Dewaxed effluent stream 128 is withdrawn from dewaxing section 126 and introduced into hydrofinishing section 130.

[0040] In embodiments, hydrofinishing section 130 includes a hydrofinishing catalyst that includes Pt, Pd, or a combination thereof on a support such as alumina or titania. In embodiments the hydrofinishing catalyst includes hydrotreating catalysts with Pt or Pd supported on alumina, amorphous alumina / silica, and / or zeolite. In embodiments, the hydrofinishing catalyst can include from 0.1 wt. % to 2.0 wt. % of hydrogenation metal relative to the weight of the support. Due to the low acidity' support, this type of catalyst causes little or no cracking of feed while being effective for reduction of single ring and multi-ring aromatics.

[0041] In some embodiments, an aromatic saturation process can optionally include multiple beds and / or sections of hydrofinishing catalyst. The multiple beds or sections can be organized in a single reactor or in a plurality of reactors.

[0042] The hydrofinishing section is operated at hydrofinishing conditions. In embodiments, the hydrofinishing section is operated at a temperature at a point in a range of 220 °C to 250 °C. Alternatively, the hydrofinishing unit is operated at a temperature at a point in a range of 220 °C(4600-19301) to 225 °C, a temperature at a point in a range of 225 °C to 230 °C, a temperature at a point in a range of 235 °C to 250 °C, or any ranges therebetween. In embodiments, the hydrofinishing unit is operated at 500 psig (3.4 MPa) to 3000 psig (20.7 MPa). Alternatively, catalytic dewaxing conditions include a hydrogen partial pressure at a point in a range of from 500 psig (3.4 MPa) to 1000 psig (6.9 MPa), 1000 psig (6.9 MPa) to 2000 psig (13.8 MPa), 2000 psig (13.8 MPa) to 3000 psig (20.7 MPa), or any ranges therebetween. In embodiments, the hydrofinishing unit is operated at an LHSV at a point in a range of 0.5-5.0 h1in the hydrofinishing section. Alternatively, the hydrofinishing unit is operated at an LHSV at a point in a range of 0.5-1.0 li '. at a LHSV point in a range of 1.0-3.0 h at a LHSV point in a range of 3.0-5.0 h '. or any LHSV ranges therebetween in the hydrofinishing section.

[0043] Additionally, or alternatively, the total pressure and / or the hydrogen partial pressure during hydrofinishing can be greater than, or possibly substantially higher than, the pressure in a catalytic dewaxing section and / or other hydroprocessing sections used to form the hydroprocessed effluent. In some aspects, the total pressure and / or hydrogen partial pressure during high pressure hydrofinishing can be at least 250 psi ('1.7 MPa) greater than the hydrogen partial pressure of a catalytic dewaxing section and / or any hydroprocessing section of the hydroprocessing that was performed to form the hydroprocessed effluent, or at least 500 psi ('3.5 MPa) greater, or at least 800 psi ('5.5 MPa) greater, or at least 1000 psi (~6.9 MPa) greater, or at least 1200 psi ('8.3 MPa) greater, or at least 1500 psi (~10.3 MPa) greater, or at least 2000 psi ('13.8 MPa) greater.

[0044] After hydrofinishing, the aromatics content of the hydrofinished lubricant boiling range product can be in a range of 0.0 wt.% to 3.0% wt .%. In embodiments, the aromatics content is 1 .5 wt. % or less, or 1.0 wt. % or less, or 0.5 wt. % or less, or 0.4 wt. % or less, or 0.3 wt. % or less, or 0.2 wt. % or less, or 0.1 wt. % or less. Additionally, or alternatively, the 3-ring aromatics content of the hydrofinished lubricant boiling range product can be at a point in a range of 0.000 wt.% to 0.100 wt.%. In embodiments, the 3-ring aromatics content is 0.050 wt. % or less, or 0.040 wt. % or less, or 0.035 wt. % or less, or 0.030 wt. % or less, or 0.025 wt. % or less, or 0.020 wt. % or less, or 0.015 wt. % or less, or 0.010 wt. % or less.

[0045] Hydrofinished effluent stream 132 is withdrawn from hydrofinishing section 130 and introduced into separation unit 134. Hydrofinished effluent stream 132 includes lubricant boiling range hydrocarbons and naphtha / distillate fuel boiling range hydrocarbons generated from dewaxing. Separation unit 134 is configured to separate the hydrofinished lubricant boiling range product from light products such as naphtha / distillate fuel boiling range. The fuel boiling point range hydrocarbons are withdrawn as fuel stream 136. In embodiments, separation unit 134 includes equipment such as strippers, distillation columns, fractionators, or any other equipment(4600-19301) suitable for separating hydrofinished lubricant boiling range product from the fuel range light ends. In embodiments, hydrofinished effluent stream 132 contains lubricant boiling range hydrocarbons corresponding to a Group II base stock and / or a Group III base stock. Group II base stocks contain at least 90 wt. % saturated molecules, less than 0.03 wt. % sulfur, and a viscosity index of at least 80 but less than 120. Group III base stocks contain at least 90 wt% saturated molecules, less than 0.03% sulfur, and a viscosity index >120. In embodiments, hydrofinished effluent stream 132 is separated into a Group II base stock and withdrawn as Group II base stock stream 138 and a Group III base stock and withdrawn as Group III base stock stream 136.Properties of Base Stock

[0046] The viscosity-temperature relationship of a lubricating oil is one of the criteria which is considered when selecting a lubricant for a particular application. Viscosity Index (VI) is an empirical, unitless number which indicates the rate of change in the viscosity of an oil within a given temperature range. Fluids exhibiting a relatively large change in viscosity with temperature are said to have a low viscosity index. A low VI oil, for example, will thin out at elevated temperatures faster than a high VI oil. Usually, the high VI oil is more desirable because it has higher viscosity at higher temperature, which translates into better or thicker lubrication film and better protection of the contacting machine elements. In embodiments, the base stocks of the present disclosure have a viscosity index (VI) of at least 80, such as a VI at a point in a range of 80-120. Alternatively, the base stocks of the present disclosure have a viscosity index at a point in a range of 80-90, at a point in a range of 90-100, at a point in a range of 100-110, at a point in a range of 110-120, at a point in a range of 120-130 or any ranges therebetween. Viscosity’ index is determined according to ASTM method ASTM D2270- 10(2016). In further embodiments, the base stock of the present disclosure is a Group II base stock and has a VI at a point in a range of 115-120. In further embodiments, the base stock of the present disclosure is a Group III base stock and has a VI at a point in a range of 120-124. In embodiments, the base stock of the present disclosure is a Group II base stock with a max VI of 120 and a KV100 in a range of 8 cSt to 13 cSt.

[0047] As used herein, “kinematic viscosity at 100° C’ will be used interchangeably with "KV 100“ and “kinematic viscosity at 40° C” will be used interchangeably with “K.V40”. KV100 is determined according to ASTM D445-24 and KV40 is determined according to ASTM D445- 24. In embodiments, the base stock has a kinematic viscosity' at 100 °C (KV100) at a point in a range of 3 cSt (centistokes) to about 8 cSt. Alternatively, the base stock has a kinematic viscosity at 100 °C at a point in a range of 3 cSt to 4 cSt, at a point in a range of 4 cSt to 5 cSt. at a point in a range of 5 cSt to 6 cSt, at a point in a range of 6 cSt to 7cSt, at a point in a range of 7 cSt to 8(4600-19301) cSt, or any ranges therebetween. In embodiments, the base stock has a kinematic viscosity' at 40 °C (KV40) at a point in a range of 20 cSt to about 40 cSt. Alternatively, the base stock has a kinematic viscosity' at 40 °C at a point in a range of 20 cSt to 25 cSt, at a point in a range of 25 cSt to 30 cSt, at a point in a range of 30 cSt to 35 cSt, at a point in a range of 35 cSt to 40 cSt, or any ranges therebetween.

[0048] In embodiments, the base stock of the present disclosure has a pour point at a point in a range of 0° C to -25° C Alternatively, the base stock of the present disclosure has pour point at a point in a range of from 0° C to -10° C, at a point in a range of from -10° C to -20° C, at a point in a range of from -20° C to -25° C, or any ranges therebetween. The pour point is measured according to ASTM D7346- 15(2021).

[0049] In embodiments, the base stock of the present disclosure has a density at a point in a range of 0.820 g / cm3to 0.850 g / cm3. Alternatively, the base stock of the present disclosure has a density7at a point in a range of 0.820 g / cm3to 0.835 g / cm3, at a point in a range of 0.835 g / cm3to 0.840 g / cm3, at a point in a range of 0.840 g / cm3to 0.845 g / cm3, at a point in a range of 0.845 g / cm3to 0.850 g / cm3, or any ranges therebetween. The density is measured according to ASTM ASTM -19D-9052.

[0050] The high temperature stability' of a lubricating oil is often an important consideration when selecting a base stock for a particular application. The Noack volatility of a base stock measures the evaporative loss of engine oils exposed to elevated temperatures. The Noack volatility is measured by ASTM D5800-21, Method B test. In embodiments, the base stocks of the present disclosure have a Noack volatility of less than 15. wt.%. In embodiments, the base stock has a Noack volatility at a point in a range of 0 wt.% to 15. wt.%. Alternatively, the base stock has a Noack volatility a point in a range of 0 wt.% to 4. wt.%, a point in a range of 4 wt.% to 8. wt.%, a point in a range of 8 wt.% to 12. wt.%. or any ranges therebetween.

[0051] The low temperature viscosity of a lubricating oil is often an important consideration when selecting a base stock for a particular application. The cold cranking simulator (CCS) as outlined in ASTM D5293-20 is used to estimate the low temperature performance of the base stock at -20 °C. In embodiments, the base stock of the present application has a CCS at -20 °C at a point in a range of 500 cP to 3000 cP. Alternatively, the base stock of the present application has a CCS at -20 °C at a point in a range of 500 cP to 1000 cP, at a point 1000 cP to 2000 cP, at a point 2000 cP to 3000 cPor any ranges therebetween.

[0052] In embodiments, the base stock of the present application has a carbon residue as measured according to ASTM D4530-15(2020) at a point in a range of 0.001 wt.% to 0.025 wt.%. Alternatively, at a point in a range of 0.001 wt.% to 0.010 wt.%., at a point in a range of 0.010(4600-19301) wt.% to 0.020 wt.%., at a point in a range of 0.020 wt.% to 0.025 wt.%.. or at a point in a range of any ranges therebetween.

[0053] Petroleum product color serves as an indication of the degree of refinement of the petroleum product. Color is determined according to ASTM D6045-20 (Saybolt color). In embodiments, the base stock of the present application has a Saybolt color of 15 to 30.

[0054] In embodiments, the base stock of the present application has a saturates content as measured according to ASTM D7419-18 of greater than 90 wt.%. Alternatively, the base stock of the present application has a saturates content of greater than 95 wt.% or greater than 99 wt .%.

[0055] In embodiments, the base stock of the present application has a total phosphorus, iron, calcium, and silicon content as determined by ASTM D5185- 18 at a point in a range of 0.0 mg / kg to 5 mg / kg. Alternatively, at a point in a range of 0.0 mg / kg to 1 mg / kg, at a point in a range of 1 mg / kg to 2 mg / kg, at a point in a range of 2 mg / kg to 3 mg / kg, at a point in a range of 3 mg / kg to 4 mg / kg, at a point in a range of 4 mg / kg to 5 mg / kg, or at a point of any sub ranges therebetween.

[0056] In embodiments, the base stock of the present application has a total acid number (TAN) as determined by ASTM D8045 at a point in a range of 0.05 to 0. 12. Alternatively, the base stock of the present application has a total acid number (TAN) at a point in a range of 0.05 to 0.07, at a point in a range of 0.07 to 0.09, at a point in a range of 0.09 to 0.12, or any ranges therebetw een.

[0057] In embodiments, the base stock of the present application has a total sulfur content of less than 5 parts per million (ppm) such as in a range of 0 ppm to 5 ppm as measured according to ASTM D2622-21. Alternatively, at a point in a range of 0 ppm to 1 ppm, a point in a range of 1 ppm to 3 ppm, a point in a range of 3 ppm to 5 ppm, or a point in a range of any ranges therebetween.

[0058] In embodiments, the base stock of the present application is substantially free of metals. The base stock has a total metal content of less than 10 ppm total combined metals such as aluminum, barium, chromium, copper, iron, lead, magnesium, manganese, molybdenum, nickel, silver, tin, titanium, vanadium, and zinc when measured according to ASTM D5185-18.Lubricant Compositions

[0059] In embodiments, the base stock of the present application is included in a lubricant composition. A base stock constitutes the major component of the engine or other mechanical component oil lubricant composition of the present disclosure and typically is present in an amount from about 50 to about 99 weight percent, preferably from about 70 to about 95 weight percent, and more preferably from about 85 to about 95 weight percent, based on the total weight of the composition. As described herein, additives constitute the minor component of the engine(4600-19301) or other mechanical component oil lubricant composition of the present disclosure and typically are present in an amount ranging from about less than 50 weight percent, preferably less than about 30 weight percent, and more preferably less than about 15 weight percent, based on the total weight of the composition.

[0060] Mixtures of base stocks can include, for example, a base stock component and a co-base stock component. The co-base stock component is present in the lubricating oils of this disclosure in an amount from about 1 to about 99 weight percent, preferably from about 5 to about 95 weight percent, and more preferably from about 10 to about 90 weight percent, based on the total weight of the composition. The base stock blend is present in the engine or other mechanical component oil lubricant composition from 15 wt.% to 99 wt. %, based on the total weight of the oil lubricant composition. Alternatively, from 15 wt.% to 30 wt. %, 30 wt.% to 60 wt. %, 60 wt.% to 80 wt. %, 80 wt.% to 90 wt. %, 90 wt.% to 95 wt. %, 95 wt.% to 99 wt. %, or any ranges therebetween.

[0061] In embodiments, the base stocks further include an additional base stock such as a group I, group II, group III, group IV, group V, or combinations thereof. In embodiments, the additional base stock is present in an amount of 1 wt.% to 99 wt.% by weight of the base stock. Alternatively, from 1 wt.% to 20 wt.%, 20 wt.% to 50 wt.%, 50 wt.% to 70 wt.%, 70 wt.% to 99 wt.%, or any ranges therebetween.

[0062] The formulated lubricating oil useful in the present disclosure may contain one or more of the other commonly used lubricating oil performance additives including but not limited to antiwear additives, detergents, dispersants, viscosity modifiers, corrosion inhibitors, rust inhibitors, metal deactivators, extreme pressure additives, anti-seizure agents, wax modifiers, other viscosity modifiers, fluid-loss additives, seal compatibility agents, lubricity agents, antistaining agents, chromophoric agents, anti-foam agents, antioxidants, anti-rust additives, antiwear additives, pour point depressant, demulsifiers, emulsifiers, densifiers, wetting agents, gelling agents, tackiness agents, colorants, and others. These additives are commonly delivered with varying amounts of diluent oil that may range from 5 w eight percent up to greater than 90 weight percent.

[0063] When lubricating oil compositions contain one or more additives, the additive(s) are blended into the composition in an amount sufficient for it to perform its intended function. As stated above, additives are typically present in lubricating oil compositions as a minor component, typically in an amount of less than 50 weight percent, preferably less than about 30 weight percent, and more preferably less than about 15 weight percent, based on the total weight of the composition. Additives are most often added to lubricating oil compositions in an amount of at(4600-19301) least 0.1 weight percent, preferably at least 1 weight percent, more preferably at least 5 weight percent.

[0064] The lube base stocks and lubricant compositions can be employed in the present disclosure in a variety of lubricant-related end uses, such as a lubricant oil or grease for a device or apparatus requiring lubrication of moving and / or interacting mechanical parts, components, or surfaces. Useful apparatuses include engines and machines. The lube base stocks of the present disclosure are suitable for use in the formulation of automotive crank case lubricants, automotive gear oils, transmission oils, many industrial lubricants including circulation lubricant, industrial gear lubricants, grease, compressor oil, pump oils, refrigeration lubricants, hydraulic lubricants and metal working fluids. Furthermore, the lube base stocks of this disclosure are derived from renewable sources; such base stocks may qualify as sustainable product and can meet “sustainability” standards set by industry groups or government regulations. The lube base stocks and lubricant compositions can be useful to reduce wear between surfaces such as metal surfaces in internal combustion engines, electric motors, crankcases, gearboxes, transmissions, differentials, and other mechanical devices. The base stock or lubricant composition containing the base stock can form a film on the surfaces of mechanical devices to protect the surfaces from wear.Additional Embodiments

[0065] Accordingly, the present disclosure provides methods to form base stocks, such as high quality Group II base stocks and Group III base stocks from used lubricating oil. The methods may include any of the various features disclosed herein, including one or more of the following statements.

[0066] Embodiment 1. A method for producing base stocks comprising: introducing a feed stream comprising pre-processed used lubricating oil and vacuum gas oil into a sour hydrocracking section; contacting the feed stream with a first demetallization and hydrotreating catalyst followed by contacting the feed stream with a first hydrocracking catalyst and hydrogen in the sour hydrocracking section at sour hydrocracking conditions effective to hydrocrack at least a portion of the feed stream to form a hydrocracked effluent; separating the hydrocracked effluent to form a hydrocrackate stream comprising lubricant boiling range hydrocarbons; introducing the hydrocrackate stream into a sweet hydrocracking section; contacting the hydrocrackate stream with a second hydrocracking catalyst and hydrogen in the sweet hydrocracking section at sweet hydrocracking conditions effective to hydrocrack at least a portion of the hydrocrackate stream to form a second hydrocrackate stream comprising additional lubricant boiling range hydrocarbons; introducing the second hydrocrackate stream into a catalytic dewaxing section; contacting the(4600-19301) second hydrocrackate stream with a dewaxing catalyst and hydrogen in the catalytic dewaxing section at catalytic dewaxing conditions effective to dewax at least a portion of the second hydrocrackate stream to from a dewaxed effluent; introducing the dewaxed effluent into a hydrofinishing section; contacting the dewaxed effluent with a hydrofinishing catalyst and hydrogen in the hydrofinishing section at hydrofinishing conditions to hydrofinish at least a portion of the dewaxed effluent to form a hydrofinished effluent; and introducing the hydrofinished effluent into a separation section and separating at least a portion of the lubricant boiling range hydrocarbons to form a base stock fraction.

[0067] Embodiment 2. The method of embodiment 1 further comprising introducing the pre- processed used lubricating oil into a demetallization section prior to introducing into the sour hydrocracking section and contacting the pre-processed used lubricating oil with a demetallization catalyst and hydrogen at hydrodemetallization conditions effective to demetallize at least a portion of the pre-processed used lubricating oil.

[0068] Embodiment 3. The method of any of embodiments 1-2 wherein the sour hydrocracking section further forms a light end fraction comprising at least one component selected from the group consisting of hydrogen sulfide, ammonia, water, and combinations thereof.

[0069] Embodiment 4. The method of embodiments 3 further comprising separating at least a portion of the light end fraction.

[0070] Embodiment 5. The method of any of embodiments 1-4 wherein the sour hydrocracking section further forms fuel range hydrocarbons selected from the group consisting of naphtha boiling range hydrocarbons, distillate fuel boiling range hydrocarbons, and combinations thereof.

[0071] Embodiment 6. The method of embodiments 5 further comprising separating at least a portion of a fuels range hydrocarbons from the hydrofinished effluent to form a fuel stream.

[0072] Embodiment 7. The method of any of embodiments 1-6 wherein the base stock fraction has a kinematic viscosity at 100 °C of about 4 to about 6 cSt as measured according to ASTM D 445-01.

[0073] Embodiment 8. The method of any of embodiments 1-7 wherein the base stock fraction has a viscosity index of about 110 to about 120 as measured according to ASTM D2270-93.

[0074] Embodiment 9. The method of any of embodiments 1-8 w herein the base stock fraction has a sulfur content less than 5 ppm as measured according to ASTM D2622.

[0075] Embodiment 10. The method of any of embodiments 1-9 w herein the base stock fraction has a saturates content of greater than 95 wt.% as measured according to ASTM D7419-18.

[0076] Embodiment 11. The method of any of embodiments 1-10 wherein the base stock fraction has a metal content less than 10 ppm as measured according to ASTM D5185-18.(4600-19301)

[0077] Embodiment 12. The method of any of embodiments 1-11 wherein the pre-processed used lubricating oil is subjected to at least one pre-processing step prior to introducing the pre- processed used lubricating oil into the sour hydrocracking section, wherein the pre-processing step is selected from the group consisting of filtering, stripping, solvent extraction, and combinations thereof.

[0078] Embodiment 13. The method of any of embodiments 1-12 wherein the feed stream comprises about 1 vol.% to about 50 vol.% of the pre-processed used lubricating oil.

[0079] Embodiment 14. The method of any of embodiments 1-13 wherein the base stock fraction is a Group II base stock and wherein the base stock fraction has a saturates content of greater than 90 wt.%, a sulfur content of less than 0.03 wt.%, and a viscosity index in a range of about 80 to about 120.

[0080] Embodiment 15. The method of any of embodiments 1-13 wherein the base stock fraction is a Group III base stock and wherein the base stock fraction has a saturates content of greater than 90 wt.%, a sulfur content of less than 0.03 wt.%, and a viscosity index in a range of about 120 to about 130.

[0081] Embodiment 16. The method of any of embodiments 1-13 wherein the base stock fraction is a Group II base stock and wherein the base stock fraction has a KV100 in a range of about 8 cSt to about 13 cSt and a viscosity index in a range of about 100 to about 120.

[0082] Embodiment 17. The method of any of embodiments 1-13 further comprising introducing the second hydrocrackate stream and / or dewaxed effluent into a hydrogenation catalyst bed.

[0083] Embodiment 18. A method for producing base stocks comprising: introducing a feed stream comprising pre-processed used lubricating oil and vacuum gas oil into a sour hydrocracking section, wherein the feed stream comprises about 5 vol.% to about 15 vol.% pre- processed used lubricating oil, and contacting the feed stream with a first demetallization and hydrotreating catalyst followed by contacting the feed stream with a first hydrocracking catalyst and hydrogen in the sour hydrocracking section at sour hydrocracking conditions effective to hydrocrack at least a portion of the feed stream to form a hydrocracked effluent; introducing the hydrocracked effluent stream into a light ends separation unit and separating a light ends fraction from the hydrocracked effluent stream and thereafter introducing the hydrocracked effluent stream into a sweet hydrocracking section and contacting the hydrocracked effluent stream w ith a second hydrocracking catalyst and hydrogen in the sweet hydrocracking section at sweet hydrocracking conditions effective to hydrocrack at least a portion of the hydrocrackate stream to form a second hydrocrackate stream comprising additional lubricant boiling range hydrocarbons; introducing the second hydrocrackate stream into a dewaxing section and contacting the second hydrocrackate(4600-19301) stream with a dewaxing catalyst, optional hydrogenation catalyst and hydrogen in the dewaxing section at catalytic dewaxing conditions effective to dewax at least a portion of the second hydrocrackate stream to from a dewaxed effluent; introducing the dewaxed effluent into a hydrofinishing section and contacting the dewaxed effluent with a hydrofinishing catalyst and hydrogen in the hydrofinishing section at hydrofinishing conditions to hydrofinishing at least a portion of the dewaxed effluent to form a hydrofinished effluent; and separating at least a portion of the lubricant boiling range hydrocarbons from the hydrofinished effluent to form a base stock fraction.

[0084] Embodiment 19. The method of embodiment 18 further comprising introducing the pre- processed used lubricating oil into a demetallization section prior to introducing into the sour hydrocracking section and contacting the pre-processed used lubricating oil with a demetallization catalyst and hydrogen at hydrodemetallization conditions effective to demetallize at least a portion of the pre-processed used lubricating oil.

[0085] Embodiment 20. The method of any of embodiments 18-19 wherein the sour hydrocracking section and / or the sweet hydrocracking section further forms fuel range hydrocarbons selected from the group consisting of naphtha boiling range hydrocarbons, di sti 11 ate fuel boiling range hydrocarbons, and combinations thereof.

[0086] Embodiment 21. The method of any of embodiments 18-20 wherein the base stock fraction has a kinematic viscosity at 100 °C of about 4 to about 6 cSt as measured according to ASTM D 445-01.

[0087] Embodiment 22. The method of any of embodiments 18-21 wherein the base stock fraction has a viscosity index of about 110 to about 120 as measured according to ASTM D2270- 93.

[0088] Embodiment 23. The method of any of embodiments 18-22 wherein the base stock fraction has a saturates content of greater than 95 wt.% as measured according to ASTM D7419- 18.

[0089] Embodiment 24. The method of any of embodiments 18-23 wherein the base stock fraction is a Group II base stock and wherein the base stock fraction has a saturates content of greater than 90 wt.%, a sulfur content of less than 0.03 wt.%. and a viscosity index in a range of about 80 to about 120.

[0090] Embodiment 25. The method of any of embodiments 18-24 wherein the base stock fraction is a Group III base stock and wherein the base stock fraction has a saturates content of greater than 90 wt.%, a sulfur content of less than 0.03 wt.%, and a viscosity index in a range of about 120 to about 130.(4600-19301)

[0091] Embodiment 26. The method of any of embodiments 18-25 wherein the base stock fraction is a Group II base stock and wherein the base stock fraction has a KV100 in a range of about 8 cSt to about 13 cSt and a viscosity index in a range of about 100 to about 120.

[0092] To facilitate a better understanding of the present invention, the following examples of certain aspects of some embodiments are given. In no way should the following examples be read to limit, or define, the entire scope of the disclosure.EXAMPLE

[0093] In this example a preprocessed used lubricating oil (UO) was blended with a wide cut vacuum gas oil at 15% volume to improve the feed qualities and reduce the boiling point conversion to achieve a target solvent dewaxed oil (SDWO) VI. The feed was utilized in a pilot plant testing of sour stage hydrotreating / hydrocracking. It was observed that there was lower conversion in the sour stage hydrotreating / hydrocracking section which reduced the 370oC+ boiling point conversion most significantly for light neutral (LN) cut by >10% thereby improving the overall total lube yield of the 5 and 12 cSt base stocks by ~8% across the entire hydroprocessing including the sweet stage hydrocracking and dewaxing.

[0094] Table 2 shows the feed qualities of the pre-processed used lubricating oil and the wide cut VGO used in this example.(4600-19301)Table 2

[0095] While the disclosure has been described with respect to a number of embodiments and examples, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope and spirit of the disclosure as disclosed herein. Although individual embodiments are discussed, the present disclosure covers all combinations of all those embodiments.

[0096] While compositions, methods, and processes are described herein in terms of ‘"comprising / ’ “containing,” “having,” or “including” various components or steps, the compositions and methods can also “consist essentially of’ or “consist of’ the various components and steps. The phrases, unless otherwise specified, “consists essentially of’ and “consisting essentially of’ do not exclude the presence of other steps, elements, or materials, whether or not,(4600-19301) specifically mentioned in this specification, so long as such steps, elements, or materials, do not affect the basic and novel characteristics of the disclosure, additionally, they do not exclude impurities and variances normally associated with the elements and materials used.

[0097] All numerical values within the detailed description are modified by “about” the indicated value, and take into account experimental error and variations that would be expected by a person having ordinary skill in the art.Many alterations, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description without departing from the spirit or scope of the present disclosure and that when numerical lower limits and numerical upper limits are listed herein, ranges from any lower limit to any upper limit are contemplated.

Claims

1. A method for producing base stocks comprising: introducing a feed stream comprising pre-processed used lubricating oil and vacuum gas oil into a sour hydrocracking section; contacting the feed stream with a first demetallization and hydrotreating catalyst followed by contacting the feed stream with a first hydrocracking catalyst and hydrogen in the sour hydrocracking section at sour hydrocracking conditions effective to hydrocrack at least a portion of the feed stream to form a hydrocracked effluent; separating the hydrocracked effluent to form a hydrocrackate stream comprising lubricant boiling range hydrocarbons; introducing the hydrocrackate stream into a sweet hydrocracking section; contacting the hydrocrackate stream with a second hydrocracking catalyst and hydrogen in the sweet hydrocracking section at sweet hydrocracking conditions effective to hydrocrack at least a portion of the hydrocrackate stream to form a second hydrocrackate stream comprising additional lubricant boiling range hydrocarbons; introducing the second hydrocrackate stream into a catalytic dewaxing section; contacting the second hydrocrackate stream with a dewaxing catalyst and hydrogen in the catalytic dewaxing section at catalytic dewaxing conditions effective to dewax at least a portion of the second hydrocrackate stream to from a dewaxed effluent; introducing the dewaxed effluent into a hydrofinishing section; contacting the dewaxed effluent with a hydrofinishing catalyst and hydrogen in the hydrofinishing section at hydrofinishing conditions to hydrofinish at least a portion of the dewaxed effluent to form a hydrofinished effluent; and introducing the hydrofinished effluent into a separation section and separating at least a portion of the lubricant boiling range hydrocarbons to form a base stock fraction.

2. The method of claim 1 further comprising introducing the pre-processed used lubricating oil into a demetallization section prior to introducing into the sour hydrocracking section and contacting the pre-processed used lubricating oil with a demetallization catalyst and hydrogen at hydrodemetallization conditions effective to demetallize at least a portion of the pre-processed used lubricating oil.

3. The method of any of claims 1-2 wherein the sour hydrocracking section further forms a light end fraction comprising at least one component selected from the group consisting of hydrogen sulfide, ammonia, water, and combinations thereof.

4. The method of claim 3 further comprising separating at least a portion of the light end fraction.

5. The method of any of claims 1 -4 wherein the sour hydrocracking section further forms fuel range hydrocarbons selected from the group consisting of naphtha boiling range hydrocarbons, distillate fuel boiling range hydrocarbons, and combinations thereof.

6. The method of claim 5 further comprising separating at least a portion of a fuels range hydrocarbons from the hydrofinished effluent to form a fuel stream.

7. The method of any of claims 1-6 wherein the base stock fraction has a kinematic viscosity' at 100 °C of about 4 to about 6 cSt as measured according to ASTM D 445-01.

8. The method of any of claims 1-7 wherein the base stock fraction has a viscosity' index of about 110 to about 120 as measured according to ASTM D2270-93.

9. The method of any’ of claims 1-8 wherein the base stock fraction has a sulfur content less than 5 ppm as measured according to ASTM D2622.

10. The method of any of claims 1-9 wherein the base stock fraction has a saturates content of greater than 95 wt.% as measured according to ASTM D7419-18.

11. The method of any' of claims 1-10 wherein the base stock fraction has a metal content less than 10 ppm as measured according to ASTM D5185-18.

12. The method of any of claims 1-11 wherein the pre-processed used lubricating oil is subjected to at least one pre-processing step prior to introducing the pre-processed used lubricating oil into the sour hydrocracking section, wherein the pre-processing step is selected from the group consisting of filtering, stripping, solvent extraction, and combinations thereof.

13. The method of any of claims 1-12 wherein the feed stream comprises about 1 vol.% to about 50 vol.% of the pre-processed used lubricating oil.

14. The method of any of claims 1-13 wherein the base stock fraction is a Group II base stock and wherein the base stock fraction has a saturates content of greater than 90 wt.%, a sulfur content of less than 0.03 wt.%, and a viscosity index in a range of about 80 to about 120.

15. The method of any of claims 1-13 wherein the base stock fraction is a Group III base stock and wherein the base stock fraction has a saturates content of greater than 90 wt.%, a sulfur content of less than 0.03 wt.%, and a viscosity index in a range of about 120 to about 130.

16. The method of any of claim 1-13 wherein the base stock fraction is a Group II base stock and wherein the base stock fraction has a KV 100 in a range of about 8 cSt to about 13 cSt and a viscosity index in a range of about 100 to about 120.

17. The method of any of claims 1-13 further comprising introducing the second hydrocrackate stream and / or dewaxed effluent into a hydrogenation catalyst bed.

18. A method for producing base stocks comprising: introducing a feed stream comprising pre-processed used lubricating oil and vacuum gas oil into a sour hydrocracking section, wherein the feed stream comprises about 5 vol.% to about 15 vol.% pre-processed used lubricating oil, and contacting the feed stream with a first demetallization and hydrotreating catalyst followed by contacting the feed stream with a first hydrocracking catalyst and hydrogen in the sour hydrocracking section at sour hydrocracking conditions effective to hydrocrack at least a portion of the feed stream to form a hydrocracked effluent; introducing the hydrocracked effluent stream into a light ends separation unit and separating a light ends fraction from the hydrocracked effluent stream and thereafter introducing the hydrocracked effluent stream into a sweet hydrocracking section and contacting the hydrocracked effluent stream with a second hydrocracking catalyst and hydrogen in the sweet hydrocracking section at sweet hydrocracking conditions effective to hydrocrack at least a portion of the hydrocrackate stream to form a second hydrocrackate stream comprising additional lubricant boiling range hydrocarbons;introducing the second hydrocrackate stream into a dewaxing section and contacting the second hydrocrackate stream with a dewaxing catalyst, optional hydrogenation catalyst and hydrogen in the dewaxing section at catalytic dewaxing conditions effective to dewax at least a portion of the second hydrocrackate stream to from a dewaxed effluent; introducing the dewaxed effluent into a hydrofinishing section and contacting the dewaxed effluent with a hydrofinishing catalyst and hydrogen in the hydrofinishing section at hydrofinishing conditions to hydrofinishing at least a portion of the dewaxed effluent to form a hydrofinished effluent; and separating at least a portion of the lubricant boiling range hydrocarbons from the hydrofinished effluent to form a base stock fraction.

19. The method of claim 18 further comprising introducing the pre-processed used lubricating oil into a demetallization section prior to introducing into the sour hydrocracking section and contacting the pre-processed used lubricating oil with a demetallization catalyst and hydrogen at hydrodemetallization conditions effective to demetallize at least a portion of the pre-processed used lubricating oil.

20. The method of any of claims 18-19 wherein the sour hydrocracking section and / or the sweet hydrocracking section further forms fuel range hydrocarbons selected from the group consisting of naphtha boiling range hydrocarbons, distillate fuel boiling range hydrocarbons, and combinations thereof.

21. The method of any of claims 18-20 wherein the base stock fraction has a kinematic viscosity at 100 °C of about 4 to about 6 cSt as measured according to ASTM D 445-01.

22. The method of any of claims 18-21 wherein the base stock fraction has a viscosity index of about 110 to about 120 as measured according to ASTM D2270-93.

23. The method of any of claims 18-22 wherein the base stock fraction has a saturates content of greater than 95 wt.% as measured according to ASTM D7419-18.

24. The method of any of claims 18-23 wherein the base stock fraction is a Group II base stock and wherein the base stock fraction has a saturates content of greater than 90 wt.%, a sulfur content of less than 0.03 wt.%, and a viscosity index in a range of about 80 to about 120.

25. The method of any of claims 18-24 wherein the base stock fraction is a Group III base stock and wherein the base stock fraction has a saturates content of greater than 90 wt.%, a sulfur content of less than 0.03 wt.%. and a viscosity index in a range of about 120 to about 130.

26. The method of any of claims 18-25 wherein the base stock fraction is a Group II base stock and wherein the base stock fraction has a KV100 in a range of about 8 cSt to about 13 cSt and a viscosity index in a range of about 100 to about 120.

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