Classifications

• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G69/00—Treatment of hydrocarbon oils by at least one hydrotreatment process and at least one other conversion process
  • C10G69/02—Treatment of hydrocarbon oils by at least one hydrotreatment process and at least one other conversion process plural serial stages only
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G45/00—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
  • C10G45/58—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to change the structural skeleton of some of the hydrocarbon content without cracking the other hydrocarbons present, e.g. lowering pour point; Selective hydrocracking of normal paraffins
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G65/00—Treatment of hydrocarbon oils by two or more hydrotreatment processes only
  • C10G65/02—Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only
  • C10G65/12—Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only including cracking steps and other hydrotreatment steps
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G47/00—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
  • C10M101/00—Lubricating compositions characterised by the base-material being a mineral or fatty oil
  • C10M101/02—Petroleum fractions
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/10—Feedstock materials
  • C10G2300/1037—Hydrocarbon fractions
  • C10G2300/1062—Lubricating oils
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/10—Feedstock materials
  • C10G2300/107—Atmospheric residues having a boiling point of at least about 538 °C
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/10—Feedstock materials
  • C10G2300/1074—Vacuum distillates
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/20—Characteristics of the feedstock or the products
  • C10G2300/201—Impurities
  • C10G2300/202—Heteroatoms content, i.e. S, N, O, P
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/20—Characteristics of the feedstock or the products
  • C10G2300/201—Impurities
  • C10G2300/205—Metal content
  • C10G2300/206—Asphaltenes
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/20—Characteristics of the feedstock or the products
  • C10G2300/30—Physical properties of feedstocks or products
  • C10G2300/302—Viscosity
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/20—Characteristics of the feedstock or the products
  • C10G2300/30—Physical properties of feedstocks or products
  • C10G2300/308—Gravity, density, e.g. API
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
  • C10G2400/10—Lubricating oil
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
  • C10M2203/00—Organic non-macromolecular hydrocarbon compounds and hydrocarbon fractions as ingredients in lubricant compositions
  • C10M2203/10—Petroleum or coal fractions, e.g. tars, solvents, bitumen
  • C10M2203/102—Aliphatic fractions
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
  • C10M2203/00—Organic non-macromolecular hydrocarbon compounds and hydrocarbon fractions as ingredients in lubricant compositions
  • C10M2203/10—Petroleum or coal fractions, e.g. tars, solvents, bitumen
  • C10M2203/102—Aliphatic fractions
  • C10M2203/1025—Aliphatic fractions used as base material
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2020/00—Specified physical or chemical properties or characteristics, i.e. function, of component of lubricating compositions
  • C10N2020/01—Physico-chemical properties
  • C10N2020/02—Viscosity; Viscosity index
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2030/00—Specified physical or chemical properties which is improved by the additive characterising the lubricating composition, e.g. multifunctional additives
  • C10N2030/02—Pour-point; Viscosity index

Definitions

• the invention concerns a process for improving base oil yields by combining an atmospheric resid feedstock with a base oil feedstock to form a combined feedstream and forming a base oil product therefrom via hydroprocessing.
• High quality lubricating base oils such as those having a viscosity index (VI) of 120 or greater (Group II and Group III), may generally be produced from high-boiling point vacuum distillates, such as vacuum gas oils (VGO), by hydrocracking to raise VI, followed by catalytic dewaxing to lower pour point and cloud point, and followed by hydrofinishing to saturate aromatics and improve stability.
• VGO vacuum gas oils
• hydrocracking high-boiling molecules are cracked to lower-boiling molecules which raises VI but also lowers the viscosity.
• the hydrocracker feed In order to make a high VI and high viscosity grade base oil at high yield, the hydrocracker feed must contain a certain quantity of high-boiling molecules.
• VGOs are limited in their ability to recover very high-boiling molecules from atmospheric resid (AR) in a vacuum column because of practical limits on temperature and pressure.
• One possible means of feeding higher-boiling molecules to the hydrocracker is to feed the AR directly, but such an approach is not normally possible or workable because the AR usually contains materials that are extremely harmful to the hydrocracker catalyst, including, e.g., nickel, vanadium, micro-carbon residue (MCR) and asphaltenes. These materials shorten the hydrocracker catalyst life to an unacceptable degree, making the use of such feeds impracticable.
• One approach to using difficult whole crude and other intermediate feeds for making base oils is to first process the feed, such as AR or vacuum resid (VR), in a solvent deasphalting (SDA) unit. Such treatment is usually necessary to separate the bulk of undesirable materials while producing a deasphalted oil (DAO) of acceptable hydrocracker feed quality.
• DAO deasphalted oil
• SDA units and the overall process approach, make them undesirable alternatives, however.
• Other approaches that attempt to minimize or eliminate the need for solvent deasphalting steps have been implemented but have not provided a clear benefit in terms of cost or other process improvements.
• Group III base oils and finished motor oils has usually required the use of expensive and supply-limited viscosity index improvers such as polyalphaolefins, or other expensive processing techniques, such as the use of gas-to-liquid (GTL) feedstocks or, e.g., through multi-hydrocracking processing of mineral oils.
• GTL gas-to-liquid
• the production of Group III base oils also generally requires high quality feedstock(s) and processing at high conversion to meet a VI targets at the expense of product yield.
• a comparatively inexpensive and suitable feedstock, and a simplified process for making such products remains to be developed and commercialized.
• the present invention is directed to a process for making a base oil product, particularly a light grade base oil product and a heavy grade base oil product through hydroprocessing of a base oil feedstream. While not necessarily limited thereto, one of the goals of the invention is to provide increased base oil yield of a heavy grade base oil product and to the production of Group II and/or Group III/III+ base oils.
• a first process according to the invention comprises making a base oil by combining an atmospheric resid feedstock and a base oil feedstock to form a base oil feedstream; contacting the base oil feedstream with a hydrocracking catalyst under hydrocracking conditions to form 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 produce a dewaxed product; and, optionally, contacting the dewaxed product with a hydrofinishing catalyst under hydrofinishing conditions to produce a hydrofinished dewaxed product.
• the invention also relates to a method for modifying a base oil process through the addition of an atmospheric resid feedstock to a base oil feedstock in a conventional base oil process that comprises subjecting a base oil feedstream to hydrocracking and dewaxing steps to form a dewaxed product comprising a light product and a heavy product.
• the modified base oil process comprises combining an atmospheric resid feedstock and a base oil feedstock to form a base oil feedstream; contacting the base oil feedstream with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracked product; separating the hydrocracked product into at least a gaseous fraction and a liquid fraction; contacting the liquid fraction with a dewaxing catalyst under hydroisomerization conditions, to produce a dewaxed product; and, optionally, contacting the dewaxed product with a hydrofinishing catalyst under hydrofinishing conditions to produce a hydrofinished dewaxed product.
• a second process according to the invention comprises making a base oil having a viscosity index of 120 or greater by contacting a base oil feedstock having a viscosity index of about 100 or greater that comprises a medium vacuum gas oil (MVGO) having a front end cut point of about 700°F or greater and a back end cut point of about 900°F or less with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracked product; separating the hydrocracked product into a gaseous fraction and a liquid fraction; dewaxing of the liquid fraction to produce a dewaxed product; and optionally, hydrofinishing of the dewaxed product to produce a hydrofinished dewaxed product.
• MVGO medium vacuum gas oil
• the invention further relates to a combined process for making a base oil product from a base oil feedstock that combines the first process and the second process to make base oils meeting Group II and/or Group III/III+ specifications.
• the combined process generally provides for making a base oil from a base oil feedstock, or a fraction thereof, and includes the use of an atmospheric resid fraction from a base oil feedstock, or a fraction thereof; separation of the base oil feedstock, or a fraction thereof, and/or the base oil atmospheric resid fraction into a narrow vacuum gas oil cut-point fraction having a front end cut point of about 700°F or greater and a back end cut point of about 900°F or less to form a medium vacuum gas oil (MVGO) fraction and a residual heavy VGO (HHVGO) fraction; and use of the HHVGO fraction as the atmospheric resid feedstock in the first process; and/or use of the MVGO fraction as the base oil feedstock in the second process.
• MVGO medium vacuum gas oil
• FIG. 1 is a general block diagram schematic illustration of a prior art process to make a base oil product.
• FIG. 2a is a general block diagram schematic illustration of an embodiment of a process to make a base oil product using a blend of VGO and atmospheric resid (VGO/AR) according to the invention.
• FIG. 2b is a general block diagram schematic illustration of an embodiment of a process to make a Group III/III+ base oil product using an MVGO fraction from an atmospheric resid and a Group II base oil product using a blend of VGO and an HHVGO residual fraction from an atmospheric resid (VGO/HHVGO) according to the invention.
• FIG. 3a is a process schematic illustration of an embodiment of a process to make a base oil product according to the invention, as described in the examples.
• FIG. 3b is a process schematic illustration of an embodiment of a process to make a base oil product according to the invention, as described in the examples.
• FIG. 4 is a process schematic illustration of an embodiment of a process to make a base oil product according to the invention, as described in the examples.
• FIG. 5 is a process schematic illustration of an embodiment of a process to make a base oil product according to the invention, as described in the examples.
• API Base Oil Categories are classifications of base oils that meet the different criteria shown in Table 1:
• API gravity refers to the gravity of a petroleum feedstock or product relative to water, as determined by ASTM D4052-11 or ASTM D1298.
• ISO-VG refers to the viscosity classification that is recommended for industrial applications, as defined by IS03448:1992.
• Viscosity index (VI) represents the temperature dependency of a lubricant, as determined by ASTM D2270-10(E2011).
• Aromatic Extraction is part of a process used to produce solvent neutral base oils. During aromatic extraction, vacuum gas oil, deasphalted oil, or mixtures thereof are extracted using solvents in a solvent extraction unit. The aromatic extraction creates a waxy raffinate and an aromatic extract, after evaporation of the solvent.
• Atmospheric resid or “atmospheric residuum” (AR) is a product of crude oil distillation at atmospheric pressure in which volatile material has been removed during distillation. AR cuts are typically derived at 650°F up to a 680°F cut point.
• VGO Vacuum gas oil
• VGO is a byproduct of crude oil vacuum distillation that can be sent to a hydroprocessing unit or to an aromatic extraction for upgrading into base oils.
• VGO generally comprises hydrocarbons with a boiling range distribution between 343°C (649°F) and 538°C (1000°F) at 0.101 MPa.
• DAO Deasphalted oil
• solvent deasphalting in a refinery is described in J. Speight, Synthetic Fuels Handbook, ISBN 007149023X, 2008, pages 64, 85-85, and 121
• “Treatment,” “treated,” “upgrade,” “upgrading” and “upgraded,” when used in conjunction with an oil feedstock, describes a feedstock that is being or has been subjected to hydroprocessing, or a resulting material or crude product, having a reduction in the molecular weight of the feedstock, a reduction in the boiling point range of the feedstock, a reduction in the concentration of asphaltenes, a reduction in the concentration of hydrocarbon free radicals, and/or a reduction in the quantity of impurities, such as sulfur, nitrogen, oxygen, halides, and metals.
• Solvent Dewaxing is a process of dewaxing by crystallization of paraffins at low temperatures and separation by filtration. Solvent dewaxing produces a dewaxed oil and slack wax. The dewaxed oil can be further hydrofinished to produce base oil.
• Hydroprocessing refers to a process in which a carbonaceous feedstock is brought into contact with hydrogen and a catalyst, at a higher temperature and pressure, for the purpose of removing undesirable impurities and/or converting the feedstock to a desired product.
• hydroprocessing processes include hydrocracking, hydrotreating, catalytic dewaxing, and hyd rofinishing.
• Hydroracking refers to a process in which hydrogenation and dehydrogenation accompanies the cracking/fragmentation of hydrocarbons, e.g., converting heavier hydrocarbons into lighter hydrocarbons, or converting aromatics and/or cycloparaffins (naphthenes) into non- cyclic branched paraffins.
• Hydrorotreating refers to a process that converts sulfur and/or nitrogen-containing hydrocarbon feeds into hydrocarbon products with reduced sulfur and/or nitrogen content, typically in conjunction with hydrocracking, and which generates hydrogen sulfide and/or ammonia (respectively) as byproducts.
• Catalytic dewaxing or hydroisomerization, refers to a process in which normal paraffins are isomerized to their more branched counterparts in the presence of hydrogen and over a catalyst.
• UV stability refers to the stability of the hydrocarbon being tested when exposed to UV light and oxygen. Instability is indicated when a visible precipitate forms, usually seen as Hoc or cloudiness, or a darker color develops upon exposure to ultraviolet light and air.
• a general description of hydrofinishing may be found in U.S. Patent Nos. 3,852,207 and 4,673,487.
• Hydrogen refers to hydrogen itself, and/or a compound or compounds that provide a source of hydrogen.
• Cut point refers to the temperature on a True Boiling Point (TBP) curve at which a predetermined degree of separation is reached.
• TBP refers to the boiling point of a hydrocarbonaceous feed or product, as determined by Simulated Distillation (SimDist) by ASTM D2887-13.
• Hydrocarbonaceous refers to a compound containing only carbon and hydrogen atoms. Other identifiers may be used to indicate the presence of particular groups, if any, in the hydrocarbon (e.g., halogenated hydrocarbon indicates the presence of one or more halogen atoms replacing an equivalent number of hydrogen atoms in the hydrocarbon).
• Group MB or “Group MB metal” refers to zinc (Zn), cadmium (Cd), mercury (Hg), and combinations thereof in any of elemental, compound, or ionic form.
• Group IVA or Group IVA metal refers to germanium (Ge), tin (Sn) or lead (Pb), and combinations thereof in any of elemental, compound, or ionic form.
• Group V metal refers to vanadium (V), niobium (Nb), tantalum (Ta), and combinations thereof in their elemental, compound, or ionic form.
• Group VI B or “Group VIB metal” refers to chromium (Cr), molybdenum (Mo), tungsten (W), and combinations thereof in any of elemental, compound, or ionic form.
• Group VIII or Group VIII metal 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 any of elemental, compound, or ionic form.
• support particularly as used in the term “catalyst support” refers to conventional materials that are typically a solid with a high surface area, to which catalyst materials are affixed. Support materials may be inert or participate in the catalytic reactions, and may be porous or non-porous.
• Typical catalyst supports include various kinds 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.
• Molecular sieve refers to a material having uniform pores of molecular dimensions within a framework structure, such that only certain molecules, depending on the type of molecular sieve, have access to the pore structure of the molecular sieve, while other molecules are excluded, e.g., due to molecular size and/or reactivity. Zeolites, crystalline aluminophosphates and crystalline silicoaluminophosphates are representative examples of molecular sieves.
• 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 a nominal viscosity of about 6 cSt at 100°C
• W600 referring to a waxy heavy base oil product having a nominal viscosity of about 12 cSt at 100°C.
• compositions and methods or processes are often described in terms of “comprising” various components or steps, the compositions and methods may also “consist essentially of” or “consist of” the various components or steps, unless stated otherwise.
• the terms “a,” “an,” and “the” are intended to include plural alternatives, e.g., at least one.
• a transition metal or “an alkali metal” is meant to encompass one, or mixtures or combinations of more than one, transition metal or alkali metal, unless otherwise specified.
• the present invention is a process for making a base oil product, comprising combining an atmospheric resid feedstock and a base oil feedstock to form a base oil feedstream; contacting the base oil feedstream with a hydrocracking catalyst under hydrocracking conditions to form 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 produce a dewaxed product; and optionally, contacting the dewaxed product with a hydrofinishing catalyst under hydrofinishing conditions to produce a hydrofinished dewaxed product.
• the base oil feedstock generally meets one or more of the following property conditions:
• API gravity in the range of 15-40 or 15-30 or 15-25, or at least 15, or at least 17, optionally, less than the atmospheric resid feedstock
• 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 feedstock; viscosity at 100°C in the range of 3-30 cSt or 3-25 cSt or 3-20 cSt, or at least 3 cSt, or at least 4 cSt; viscosity at 70°C in the range of 5-25 cSt or 5-20 cSt or 5-15 cSt, or at least 5 cSt, or at least 6 cSt; hot C 7 asphaltene content in the range of 0.01-0.3 wt.% or 0.01-0.2 wt.% or 0.02-0.15 wt.%, or less than 0.3 wt.
• wax content in the range of 5-40 wt.% or 5-30 wt.% or 10-25 wt.%, or at least 5 wt.% or at least 10 wt.%, or at least 15 wt.%, or, optionally, greater than the wax content of the base oil feedstock; 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; 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
• 1050+°F content in 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 feedstock.
• Suitable base oil feedstocks may be from any crude oil feedstock, or a fraction thereof, including hydroprocessed intermediate streams or other feeds. Generally, the base oil feedstock contains materials boiling within the base oil range. Feedstocks may include atmospheric and vacuum residuum from a variety of sources, whole crudes, and paraffin-based crudes.
• the atmospheric resid (AR) feedstock generally meets one or more of the following property conditions:
• API gravity in the range of 20-60 or 20-45 or 25-45, or at least 20, or at least 22, or, optionally, greater than the API of the base oil feedstock;
• VI in the range of 50-200 or 70-190 or 90-180, or at least 80, or, optionally, greater than the VI of the base oil feedstock; viscosity at 100°C in the range of 3-30 cSt or 3-25 cSt or 3-20 cSt, or at least 3 cSt, or at least 4 cSt; viscosity at 70°C in the range of 5-25 cSt or 5-20 cSt or 5-15 cSt, or at least 5cSt, or at least 6 cSt; hot C 7 asphaltene content in the range of 0.01-0.3 wt.% or 0.01-0.2 wt.% or 0.02-0.15 wt.%, or less than 0.3 wt.
• wax content in the range of 5-40 wt.% or 5-30 wt.% or 10-25 wt.%, or at least 5 wt.% or at least 10 wt.%, or at least 15 wt.%, or, optionally, greater than the wax content of the base oil feedstock; 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; 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
• 1050+°F content in 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 feedstock.
• AR feedstocks having property characteristics described herein may be advantageously derived from a light tight oil (LTO, e.g., shale oil typically having an API of >45).
• Suitable feedstocks may be Permian Basin feedstocks and elsewhere, including Eagle Ford, Avalon, Magellan, Buckeye, and the like.
• Both the base oil feedstock and the atmospheric resid feedstock may have any of the foregoing properties within any of the noted broad and narrower ranges and combinations of such ranges.
• the base oil feedstream generally comprises 10--60 wt.% atmospheric resid feedstock and 40-90 wt.% base oil feedstock, or 10-40 wt.% atmospheric resid feedstock and 60-90 wt.% base oil feedstock, or 10-30 wt.% atmospheric resid feedstock and 70-90 wt.% base oil feedstock, or 30-60 wt.% atmospheric resid feedstock and 40-70 wt.% base oil feedstock, or 40-60 wt.% atmospheric resid feedstock and 40--60 wt.% base oil feedstock.
• the base oil feedstream does not contain an added whole crude oil feedstock, and/or does not contain a vacuum residue feedstock, and/or does not contain a deasphalted oil feedstock component, and/or contains only atmospheric resid feedstock and base oil feedstock.
• the process need not include recycle of a liquid feedstock as part of the base oil feedstream or as either or both of the atmospheric resid feedstock and the base oil feedstock. In certain embodiments, recycle of one or more intermediate streams may be desired, however.
• the base oil feedstock may comprise vacuum gas oil, or consist essentially of vacuum gas oil, or consist of vacuum gas oil.
• the vacuum gas oil may be a heavy vacuum gas oil obtained from vacuum gas oil that is cut into a light fraction and a heavy fraction, with the heavy fraction having a cut point temperature range of about 950-1050°F.
• the dewaxed product and/or the hydrofinished dewaxed product is typically obtained as a light base oil product and a heavy base oil product.
• the light base oil product generally has a nominal viscosity in the range of 4-8 cSt or 5-7 cSt at 100°C and/or with the heavy base oil product generally having a nominal 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 a nominal viscosity of about 6 cSt at 100°C, and/or at least a heavy product having a nominal viscosity of about 12 cSt at 100°C, or a combination thereof.
• the yield of the heavy base oil product relative to the light base oil product may be increased by at least about 2 Lvol.%, or at least about 5 Lvol.% (liquid volume %) compared with the same process that does not include the atmospheric resid feedstock in the lubricating oil feedstream.
• the yield of the heavy base product may be increased by at least about 10 Lvol.%, or at least about 20 Lvol.%, or at least about 30 Lvol.%, or at least about 40 Lvol.%, compared with the same process that does not include the atmospheric resid feedstock in the base oil feedstream.
• the invention concerns a method for modifying a conventional or existing base oil process.
• a base oil process that comprises subjecting a base oil feedstream to hydrocracking and dewaxing steps to form a dewaxed product comprising a lighter product and a heavier product may be modified according to the invention by combining an atmospheric resid feedstock with a base oil feedstock to form the base oil feedstream and subjecting the base oil feedstream comprising the atmospheric resid feedstock to the hydrocracking and dewaxing steps of the base oil process to produce a dewaxed product.
• the dewaxed product may be optionally further contacted with a hydrofinishing catalyst under hydrofinishing conditions to produce a hydrofinished dewaxed product.
• the invention further relates to a process for making a base oil, 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, wherein the base oil feedstock comprises vacuum gas oil having a front end cut point of about 700°F or greater and a back end cut point 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 produce a dewaxed product; and optionally, contacting the dewaxed product with a hydrofinishing catalyst under hydrofinishing conditions to produce a hydrofinished dewaxed product; wherein, the dewaxed product and/or the hydrofinished dewaxed product has a viscosity index of 120 or greater after dewaxing.
• the dewaxed product and/or the hydrofinished dewaxed product may have a viscosity index of 130 or greater after dewaxing, or 135 or greater after dewaxing, or 140 or greater after dewaxing.
• the hydrocracked product may have a viscosity index of at least about 135, or 140, or 145, or 150.
• the dewaxed products prepared by the process may be a Group III or Group 111+ product.
• a vacuum gas oil having a front end cut point of about 700°F or greater and a back end cut point of about 900°F or less herein referred to as a medium vacuum gas oil (MVGO) provides an improved waxy product yield at a Group III or Group 111+ viscosity of 4cSt 100°C of the MVGO that is at least about 3 lvol.% greater than the same process that does not include the MVGO as the base oil feedstock.
• MVGO medium vacuum gas oil
• the invention further relates to a process that combines the two process aspects, i.e., in which a feedstock is used to derive the narrow cut-point fraction and the same or a different feedstock is used for the atmospheric resid fraction.
• the combined process for making a base oil from a base oil feedstock, or a fraction thereof comprises providing an atmospheric resid fraction from a base oil feedstock, or a fraction thereof; separating the base oil feedstock, or a fraction thereof, and/or the base oil atmospheric resid fraction into a narrow vacuum gas oil cut- point fraction having a front end cut point of about 700°F or greater and a back end cut point of about 900°F or less to form an MVGO fraction and a residual FIFIVGO fraction; using the FIFIVGO fraction as the atmospheric resid feedstock in the first process to prepare a dewaxed product and/or hydrofinished dewaxed product; and/or using the MVGO fraction as the base oil feedstock in a second process to prepare a dewaxed product and/or hydrofinished dewaxed product having a viscosity index of 120 or greater after dewaxing.
• the base oil feedstock may comprise tight oil, particularly a light tight oil, or a fraction thereof.
• the narrow vacuum gas oil cut- point fraction may also be derived from the atmospheric resid fraction, including an atmospheric resid fraction derived from light tight oil.
• the fractionation of the AR feedstock into MVGO and FIFIVGO fractions provides the ability to produce Group III/III+ base oil product while still allowing the FIFIVGO fraction to be used with a conventional VGO base oil feedstock to produce a Group II base oil product.
• the use of MVGO to produce Group III/III+ base oil product results in greater yields of such products.
• FIG. 2a An illustration of a method or process according to an embodiment of the invention is shown schematically in FIG. 2a, in which conventional base oil hydrotreating, hydrocracking, hydrodewaxing, and hydrofinishing process steps, conditions, and catalysts are used.
• FIG. 2a shows the use of a feed blend of VGO and atmospheric resid (AR) where the conventional process typically uses VGO base oil feedstock.
• AR atmospheric resid
• FIG 2b further illustrates the use of an AR feedstock to form a medium vacuum gas oil fraction (MVGO) and a heavy VGO fraction (FIFIVGO), with the MVGO fraction feedstream being used to produce a Group III/III+ base oil product and the FIFIVGO fraction feedstream being combined with a conventional VGO base oil feedstock to produce a Group II base oil product.
• MVGO medium vacuum gas oil fraction
• FIFIVGO heavy VGO fraction
• Catalysts suitable for use as the hydrocracking, dewaxing, and hydrofinishing catalysts in the process and method and associated process conditions are described in a number of publications, including, e.g., US Patent Publication Nos.
• Catalysts suitable for hydrocracking comprise materials having hydrogenation- dehydrogenation activity, together with an active cracking component support.
• Such catalysts are well described in many patent and literature references.
• Exemplary cracking component supports include silica-alumina, silica- oxide zirconia composites, acid-treated clays, crystalline aluminosilicate zeolitic molecular sieves such as zeolite A, faujasite, zeolite X, and zeolite Y, and combinations thereof.
• Flydrogenation-dehydrogenation components of the catalyst preferably comprise a metal selected from Group VIII metals and compounds thereof and Group VIB metals and compounds thereof.
• 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 a hydrocracking catalyst which would be suitable for use in the hydrocracking process step are the combinations of nickel-tungsten-silica-alumina, nickel- molybdenum-silica-alumina and cobalt-molybdenum-silica-alumina. Such catalysts may vary in their activities for hydrogenation and for cracking and in their ability to sustain high activity during long periods of use depending on their compositions and preparation.
• Typical hydrocracking reaction conditions include, for example, a temperature of from 450°F to 900° F (232°C to 482°C), e.g., from 650°F to 850°F (343°C to 454°C); a pressure of from 500 psig to 5000 psig (3.5 MPa to 34.5 MPa gauge), e.g., from 1500 psig to 3500 psig (10.4 MPa to 24.2 MPa gauge); a liquid reactant feed rate, in terms of liquid hourly space velocity (LHSV) of from 0.1 hr 1 to 15 hr 1 (v/v), e.g., from 0.25 hr 1 to 2.5 hr 1 ; a hydrogen feed rate, in terms of H 2 /hydrocarbon ratio, of from 500 SCF/bbl to 5000 SCF/bbl (89 to 890 m 3 H 2 /m 3 feedstock) of liquid base oil (lubricating) feedstock, and/or a hydrogen partial pressure of
• Hydrodewaxing is used primarily for reducing the pour point and/or for reducing the cloud point of the base oil by removing wax from the base oil.
• dewaxing uses a catalytic process for processing the wax, with the dewaxer feed is generally upgraded prior to dewaxing to increase the viscosity index, to decrease the aromatic and heteroatom content, and to reduce the amount of low boiling components in the dewaxer feed.
• Some dewaxing catalysts accomplish the wax conversion reactions by cracking the waxy molecules to lower molecular weight molecules.
• isomerization encompasses a hydroisomerization process, for using hydrogen in the isomerization of the wax molecules under catalytic hydroisomerization conditions.
• Dewaxing generally includes processing the dewaxer feedstock by hydroisomerization to convert at least the n-paraffins and to 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 on a support.
• Suitable supports include, but are not limited to, zeolites CIT-1, IM-5, SSZ-20,SSZ- 23,SSZ-24, SSZ-25,SSZ-26, SSZ-31, SSZ-32, SSZ-32,SSZ-33,SSZ-35, SSZ-36,SSZ-37, SSZ-41, SSZ -42, SSZ- 43, SSZ-44, SSZ-46, SSZ-47, SSZ-48, SSZ-51, SSZ-56, SSZ-57, SSZ-58, SSZ-59, SSZ-60, SSZ-61, SSZ-63, SSZ- 64, SSZ-65, SSZ-67, SSZ-68, SSZ-69, SSZ-70, SSZ-71, SSZ-74, SSZ-75, SSZ-76, SSZ-78, SSZ-81, SSZ- 82,
• Isomerization may involve also a Pt and/or Pd catalyst supported on an acidic support material such as beta or zeolite Y molecular sieves, silica, alumina, silica-alumina, and combinations thereof.
• acidic support material 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, e.g., US. Pat. Nos. 4,859,312; 5,158,665; and 5,300,210.
• Hydrodewaxing conditions generally depend on the feed used, the catalyst used, whether or not the catalyst is sulfided, the desired yield, and the desired properties of the base oil. Typical conditions include a temperature of from 500°F to 775°F (260°C to 413°C); a pressure of from 15 psig to 3000 psig (0.10 MPa to 20.68 MPa gauge); a LHSV of from 0.25 hr 1 to 20 hr 1 ; and a hydrogen to feed ratio of from 2000 SCF/bbl to 30,000 SCF/bbl (356 to 5340 m 3 H 2 /m 3 feed). Generally, hydrogen will be separated from the product and recycled to the isomerization zone. Suitable dewaxing conditions and processes are described in, e.g., U.S. Pat. Nos. 5,135,638; 5,282,958; and 7,282,134.
• Waxy products W220 and W600 may be dewaxed to form 220N and 600N products that may be suitable (or better suited) for use as a lubricating base oil or in a lubricant formulation.
• the dewaxed product may be mixed or admixed with existing lubricating base oils in order to create new base oils or to modify the properties of existing base oils, e.g., to meet particular target conditions, such as viscometric or Noack target conditions, for particular base oil grades like 220N and 600N.
• Isomerization and blending can be used to modulate and maintain pour point and cloud point of the base oil at suitable values.
• Normal paraffins may also be blended with other base oil components prior to undergoing catalytic isomerization, including blending normal paraffins with the isomerized product.
• Lubricating base oils that may be produced in the dewaxing step may be treated in a separation step to remove light product.
• the lubricating base oil may be further treated by distillation, using atmospheric distillation and optionally vacuum distillation to produce a lubricating base oil.
• Typical hydrotreating conditions vary over a wide range.
• the overall LHSV is about 0.25 hr 1 to 10 hr 1 (v/v), or alternatively about 0.5 hr 1 to 1.5 hr 1 .
• the total pressure is from 200 psig to 3000 psig, or alternatively ranging from about 500 psia to about 2500 psia.
• Hydrogen feed rate in terms of H 2 /hydrocarbon ratio, are typically from 500 SCF/Bbl to 5000SCF/bbl (89 to 890 m 3 H 2 /m 3 feedstock), and are often between 1000 and 3500 SCF/Bbl.
• Reaction temperatures in the reactor will typically be in the range from about 300°F to about 750°F (about 150°C to about 400°C), or alternatively in the range from 450°F to 725°F (230°C to 385°C).
• layered catalyst systems may be used comprising hydrotreating (HDT, HDM, DEMET, etc.), hydrocracking (HCR), hydrodewaxing (HDW), and hydrofinishing (HFN) catalysts to produce intermediate and/or finished base oils using single or multireactor systems.
• a typical configuration includes two reactors with the first reactor comprising layered catalysts providing DEMET, HDT pretreatment, HCR, and/or HDW activity. Differing catalysts performing similar functions, e.g., different levels of hydrocracking activity, may be used as well, e.g., in different layers within a single reactor or in separate reactors.
• VGO vacuum gas oil
• AR atmospheric resid
• Research unit process conditions used included 0.5 LHSV _1 , reactor FL partial pressure of 1750 psia, hydrogen feed gas oil (recycle) ratio of 4500 scfb, and reactor temperatures in range of 700-770+°F, with the downstream reactor R2 temperature being maintained at 20°F hotter than the upstream R1 reactor.
• An ascending temperature profile was imposed, 120°F and 40°F DT for R1 and R2, respectively.
• Waxy product target viscosity indexes (Vi's) were set at 109 at 6.0 cSt at 100°C (W220) and 11.8 cSt at 100°C (W600).
• Bench scale process conditions used included 0.5 LHSV 1 , reactor pressure of 1850 psig, hydrogen feed gas oil ratio of 4500 scfb, and reactor temperatures in range of 700-770+°F, with the downstream reactor R2 temperature being maintained at 20°F hotter than the upstream R1 reactor.
• Waxy product target viscosity indexes (Vi's) were set at 109 at 6.1 cSt at 100°C (220R) and 11.8 cSt at 100°C (600R).
• the catalyst loading in each of reactors R1 and R2 was a conventional scheme for base oil production comprising layered hydrometallation, hydrotreating, and hydrocracking catalysts.
• Typical configurations included layered catalyst systems comprising one or more DEMET layers, high activity HCR/H DT, HCR, and low activity HCR catalysts for both R1 and R2.
• FIG's 3a, 3b, 4, and 5 each show feedstreams 10 and Fh inlet 11 to each of reactors R1 and R2, and other intermediate flow streams 20, 30, FL recycle stream 31, whole liquid product (WLP) stream 32 that are sent to separators and/or condensers (Cl to C4, SI, and V3) to provide the respective product streams C2B, C3B, C40, C4B, STO, STB, V30, and V3B shown in each figure and as noted in the following examples.
• WLP whole liquid product
• VGO Vacuum Gas Oil
• VGO feedstock A sample of vacuum gas oil (VGO) feedstock from a commercially available source used to produce base oil products was obtained and analyzed as a comparative base case.
• the VGO feedstock was used in the following examples according to the process configurations shown in FIG's. 3a, 3b, 4, and 5.
• the properties of this VGO feedstock are shown in Table 1.
• VGO Vacuum Gas Oil
• Viscosity Index, VI (D2270) 73 100 63 72 69 Viscosity, 100°C (cSt) 13.68 6.912 11.99 11.63 11.12 Viscosity, 70°C (cSt) 37.28 15.21 32.4 30.59 29.12
• blend feedstock samples AR1 to AR5 of the atmospheric resids with vacuum gas oil (VGO) of example 3 were evaluated for Group II base oil production according to the process represented by FIG. 3b.
• Group II results were also obtained using the VGO feedstock of example 1 (according to the process of FIG. 3a) for comparison.
• Bench scale process conditions used included 0.5 LHSV , reactor pressure of 1850 psig, hydrogen feed gas oil ratio of 4500 scfb, and reactor temperatures in range of 700-770+°F, with the downstream reactor R2 temperature being maintained at 20°F hotter than the upstream R1 reactor.
• Waxy product target viscosity indexes (Vi's) were set at 109 at 6.1 cSt at 100°C (220R) and 11.8 cSt at 100°C (600R).
• Table 4a Base Oil Production for ARl/VGO (wt/wt) blend Feed VGO % ARl/55% VGO
• Table 4b presents the results obtained for atmospheric resid samples AR2 and AR3 that are each blended with vacuum gas oil (VGO).
• VGO vacuum gas oil
• the AR3/VGO blend (88-342-3726-3750) showed significant actual waxy W600R yield improvement compared to VGO feed alone, 31.9% vs. 18.6%.
• the total actual waxy base oil yield remained the same, while the waxy products from the AR3/VGO blend showed slightly higher nitrogen content.
• Table 4c presents the results obtained for atmospheric resid samples AR4 and AR5 that are each blended with vacuum gas oil (VGO). As shown, two separate runs were performed at different hydrocracking severities for each of the VGO comparative feed and the AR4/VGO and AR5/VGO blends.
• VGO vacuum gas oil
• Results from Table 4c provide a basis for comparison of waxy base oil yields at a viscosity index (VI) of 109 for W220 for AR2/VGO, AR4/VGO, and AR5/VGO blends, as shown in Table 4d.
• VI viscosity index
• the 50% AR2/VGO blend feed showed a waxy base oil yield improvement in W600 yield of 33.7% compared with a W600 yield of 25.8% for VGO feed alone that does not include the atmospheric resid AR2 component.
• a total waxy base oils yield of 68.7% for the AR2/VGO blend was obtained compared with a total waxy base oils yield of 66.1% when the feed did not contain the AR2 blend component.
• the 20% AR4/VGO blend also showed improvements in both W600 yield of the AR4/VGO blend compared with the VGO feed by itself ( 28.4% vs. 25.8%), in W220 yield of the AR4/VGO blend compared with the VGO feed by itself (42.9% vs. 40.3%), and the total waxy base oil yield of the AR4/VGO blend compared with the VGO feed by itself (71.3% vs. 66.1%).
• the 20% AR5/VGO showed improvement in W220 yield of the AR5/VGO blend compared with the VGO feed by itself (44.4% vs.40.3%) and in total waxy base oil W600 yield of the AR5/VGO blend compared with the VGO feed by itself (68.1% vs. 66.1%).
• Samples of atmospheric resid (AR) were evaluated to provide medium grade vacuum gas oils (MVGO) for use in producing group III/III+ base oils.
• the MVGO samples were derived from the corresponding AR samples as distillation cuts in the following ranges: AR2 cut range of 717-876°F; AR4 cut range of 725-882°F; and, AR5 cut range of 716-882°F.
• Table 5a presents properties of the AR samples AR2, AR4, and AR5 and the corresponding MVGO derived cuts MVG02, MVG04, and MVG05. Properties for the comparative vacuum gas oil (VGO) are also included.
• AR4, and AR5 feeds designated as MVG02, MVG04, and MVG05 feeds, respectively.
• Table 5a Properties of Atmospheric Resid (AR) and MVGO Feeds
• Table 5b Comparison of Yields for VGO and MVGO Feeds for Group III Base Oil Production
• Samples of atmospheric resid feed sample AR3 were evaluated to provide medium grade vacuum gas oils (MVGO) for use in producing group III/III+ base oils.
• MVGO samples were derived from the corresponding AR3 samples as distillation cuts in the 725-895 °F range, designated as MVG03b (broad temperature range cut), and 725-855°F, designated as MVG03n (narrow temperature range cut).
• Table 6 presents the results using the MVG03b and MVG03n feeds to produce group III 4cSt base oils using the process configuration of FIG. 3a.
• Properties for the comparative vacuum gas oil (VGO) are also included.
• Both MVGO feeds MVG03b and MVG03n provided increased waxy Group III product yield for 4 cSt base oil production, with the broad cut MVG03b showing a 4.5 lvol.% and the narrow MVGO cut MVG03n showing a 6.6 lvol.% increase compared against the use of the vacuum gas oil (VGO) feed.
• Table 6 - MVGO Use for Group III 4 cSt Base Oil Production
• Example 7 Evaluation of Heavy-Heavy Vacuum Gas Oil (HHVGO) Fractions Derived from Atmospheric Resids (AR) to Produce Group II Base Oils
• HHVGO Heavy-Heavy Vacuum Gas Oil
• Table 7a presents the properties of the HHVGO samples HHVG02, HHVG04, and HHVG05 and blend of 9%HHVGO/VGO and 9%HHVGO/VGO. Properties of the comparative VGO feed are also shown.
• Table 7b presents the results using the HHVGO/VGO blend feeds to produce group II base oils using the process configuration of FIG. 5.
• Results for the comparative vacuum gas oil (VGO) are also included.
• the results are further summarized in Table 7c. Both HHVGO feeds, i.e.,
• 9% HHVG02/VGO and 9% HHVG04/VGO provided comparable waxy Group II base oil product yields compared with the use of the VGO feed by itself.
• the combination of using an MVGO cut to produce a Group III base oil and of using the remaining HHVGO fraction to produce a Group II base oil therefore provides technical and economic advantages compared with the use of a vacuum gas oil feed.
• Table 7b Waxy Base Oil Yields from HHVGO/VGO Blend Feeds
• Table 7b (continued) Waxy Base Oil Yields from HHVGO/VGO Blend Feeds
• Table 7c Yield Comparison for HHVGO/VGO Blend Feeds at 109 VI W220

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