TW202246473A - Process for making heavy grade base oil products - Google Patents

Abstract

An improved process for making a heavy base oil from a base oil feedstream comprising an atmospheric resid feedstock, and, optionally, a base oil feedstock, via hydroprocessing. The process generally involves subjecting a base oil feedstream comprising the atmospheric resid to hydrocracking and dewaxing steps, and optionally to hydrofinishing, to produce base oil product(s) including a heavy grade base oil product having a viscosity of at least about 12.7 cSt at 100°C. The invention is useful to make heavy grade base oil products, as well as Group II and/or Group III/III+ base oils.

Description

Process used to manufacture heavy grade base oil products

The present invention relates to a process for producing a heavy grade base oil product by: combining an atmospheric resid feedstock with a base oil feedstock to form a combined feed stream; and forming a heavy grade base oil product from the combined feed stream by hydrogenation. Quality grade base oil products.

High quality lubricating base oils such as those base oils (Groups II and III) with a viscosity index (VI) of 120 or higher can usually be vacuum distilled from high boiling point oils such as vacuum gas oil (VGO) by Product production: hydrocracking to increase VI, followed by catalytic dewaxing to reduce pour point and cloud point, and then hydrofinishing to saturate aromatics and improve stability. In hydrocracking, high boiling molecules are cracked into lower boiling molecules, which increases VI but also reduces viscosity and yield. In order to produce high-VI and high-viscosity base oils with high yields, the feed to the hydrocracker must contain a certain amount of high-boiling molecules. Typically, VGO has limited ability to recover very high boiling point molecules from atmospheric resid (AR) in vacuum columns due to practical limitations in temperature and pressure. One possible way of feeding higher boiling molecules to the hydrocracker is to feed the AR directly, but this is usually not possible or feasible because the AR usually contains materials that are extremely harmful to the hydrocracker catalyst, including Examples include nickel, vanadium, micro carbon residue (MCR) and asphaltenes. These materials shorten the life of hydrocracker catalysts to unacceptable levels, making the use of these feeds impractical.

One approach to using difficult whole crude oils and other intermediate feedstocks to make base oils is to first process the feedstock, such as AR or vacuum resid (VR), in a solvent deasphalting (SDA) unit. Such treatment is usually necessary to separate most of the unwanted materials while producing a deasphalted oil (DAO) of acceptable hydrocracker feed quality. However, the extremely high capital requirements and high operating costs of such SDA devices, as well as the overall process approach, make them an undesirable alternative. Other approaches have been implemented that attempt to minimize or eliminate the need for a solvent deasphalting step, but have not yet provided significant benefits in terms of cost or other process improvements.

The production of Group III base stocks and finished motor oils often requires the use of expensive and limited supply viscosity index improvers, such as polyalphaolefins, or other costly processing techniques, such as using gas-to-liquid (GTL) feedstocks or, for example, via multiple processing of mineral oils. Hydrogen cracking treatment. Production of Group III base oils also typically requires high-quality feedstock and high-conversion processing at the expense of product yield to meet VI targets. However, despite continuous industry efforts, relatively cheap and suitable raw materials and simplified manufacturing processes for manufacturing such products have yet to be developed and commercialized.

Extra heavy, higher grade base oils are generally not economically produced using conventionally available crude oils, in part because such feedstocks generally do not contain sufficient amounts of molecular species to produce such heavy grades. Typical Vacuum Gas Oil (VGO) feed cuts used to make Heavy Neutral (HN) base oils have an endpoint of only 1050 to 1100°F, and the viscosity of the base oil product is limited to the range of 11 to 12 cSt (at 100°C down measurement). The molecules required to make the heavier grades of base oil are not present in significant amounts in such typically available feed fractions. Processing such feeds to produce heavier fractions introduces excess heteroatoms, such as nitrogen, and aromatics, and requires extensive pretreatment and intensive conversions. The resulting low yields would make such a process uneconomical using typically available feedstocks. Thus, a process utilizing a feedstock suitable for producing a heavier grade of base oil, such as a feedstock with higher purity, lower aromatic content, and higher VI in the high boiling range of interest, as a source for producing a heavy base oil product would be feasible.

Despite the progress in producing base oils from different and challenging feedstocks, there remains a need for improved processes to utilize different feedstocks and increase the yield of valuable heavier grade base oil products.

The present invention relates to a process for the manufacture of base oil products, particularly heavy grade base oil products, via hydrogenation of a base oil feed stream. Although not necessarily limited thereto, one of the objectives of the present invention is to provide increased base oil yields for extra heavy grade base oil products.

In general, the first process according to the invention comprises the manufacture of base oil by providing an atmospheric residual feedstock optionally combined with conventional base oil feedstock as a base oil feed stream; subjecting the base oil under hydrocracking conditions to contacting a base oil feed stream with a hydrocracking catalyst to form a hydrocracked product; separating the hydrocracked product into a gaseous fraction and a liquid fraction; subjecting the liquid fraction to the hydrodewaxing catalyst under hydroisomerization conditions contacting to produce a dewaxed product; and, optionally, contacting the dewaxed product with a hydrofinishing catalyst under hydrofinishing conditions to produce a hydrofinishing dewaxed product. The process produces at least one base oil product comprising a heavy base oil product having a viscosity at 100°C of at least about 12.7 cSt, or at least about 13 cSt, or at least about 13.3 cSt. In some aspects, the process may also provide beneficial yield improvements for one or more base oil products compared to using a feedstock that does not include an atmospheric resid feedstock component.

The present invention also relates to a method for modifying a base oil process comprising subjecting a base oil feed stream to hydrocracking and A dewaxing step to form a dewaxed product comprising light products and heavy products. Accordingly, the modified base oil process comprises: combining an atmospheric resid feedstock and a base oil feedstock to form a base oil feed; contacting the base oil feed stream 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 hydrodewaxing catalyst under hydroisomerization conditions to produce a dewaxed product; and, optionally, at The dewaxed product is contacted with a hydrofinishing catalyst under hydrofinishing conditions to produce a hydrofinished dewaxed product. The modified process produces at least one base oil product having a viscosity of at least about 13 cSt at 100°C and may also provide beneficial productivity improvement.

The present invention further relates to a process for producing a heavy base oil having a viscosity of at least about 13 cSt at 100°C by subjecting a base oil comprising an atmospheric resid feedstock and optionally a base oil feedstock to The stream is separated into a vacuum gas oil with a front cut point of about 700°F or higher and a back end cut point of about 900°F or lower to form a medium vacuum gas oil MVGO fraction and a heavy vacuum gas oil HVGO ; contacting the HVGO fraction with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracking product; separating the hydrocracking product into a gas fraction and a liquid fraction; hydrodewaxing the liquid fraction to produce a dewaxed product; and optionally, hydrofinishing the dewaxed product to produce a hydrofinished dewaxed product. The process produces at least one base oil product comprising a viscosity at 100°C of at least about 12.7 cSt or at least about 13 cSt or at least about 13.3 cSt heavy base oil product.

The present invention further provides a process for producing a base oil product from a medium vacuum gas oil MVGO fraction by contacting the MVGO fraction 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, under hydrofinishing conditions using The dewaxed product is contacted with a hydrofinishing catalyst to produce a hydrofinished dewaxed product; wherein the viscosity index of the dewaxed product and/or the hydrofinished dewaxed product is 120 or higher after dewaxing.

Cross-references to related applications

This application claims the benefit of priority to U.S. Provisional Application No. 63/141,955, filed January 26, 2021, the disclosure of which is incorporated herein in its entirety.

Although illustrative examples of one or more aspects are provided herein, the disclosed processes can be implemented using a number of techniques. The disclosure is not limited to the illustrative or specific embodiments, drawings and techniques illustrated herein, including any exemplary designs and embodiments illustrated and described herein, and may be incorporated within the scope of the accompanying technical solutions along with equivalents thereof Modifications in its entirety.

Unless otherwise stated, the following terms, terms, and definitions apply to this disclosure. If a term is used in this disclosure, but is not expressly defined herein, the definition from the IUPAC General Catalog of Chemical Terms, 2nd Edition (1997) applies, provided that the definition differs from any other disclosure or definition applied herein conflict, or make unclear or invalid any technical solution applying this definition. To the extent that any definition or usage provided by any document incorporated herein by reference conflicts with the definition or usage provided herein, the definition or usage provided herein shall be understood to apply.

"API base oil category" refers to the base oil classification that meets the different standards shown in Table 1: Table 1 : Base oil raw material properties (raw material with a viscosity of 4 cSt at 100°C, without additives) group naming composition Sulfur, wt% Saturated hydrocarbons, wt% Viscosity index, VI volatility,% polarity Pour point, °C Flash point, °C Class I Distillation, solvent refining, ≥10% aromatics >0.03 and/or <90 80-119 15-20 high school -5 to 15 100 Class II Distillation, solvent refining, hydrocracking, <10% aromatics ≤0.03 And ≥90 80-119 10-15 middle -10 to -20 170 Class III Distillation, solvent refining, severe hydrocracking, <10% aromatics ≤0.03 And ≥90 ≥120 5-15 middle -10 to 25 190 Class III+ Group III oils additionally hydroisomerized or otherwise treated, <1% aromatics -- -- ≥130 ≤5 Low -15 to -30 200 Class IV Polyalphaolefin (PAO) 100% catalytic synthesis of olefins derived from pyrolysis wax -- -- 135-140 1.8 Low -53 270 Class V 100% synthesized by catalytic reaction of acids and alcohols; all base oils excluded from groups I-IV -- -- 140 1.0 high -twenty one 260

"API specific gravity" refers to the specific gravity of petroleum raw materials or products relative to water, as determined by ASTM D4052-11 or ASTM D1298, usually using commercially available petroleum analysis equipment.

"ISO-VG" refers to the viscosity classification recommended for industrial applications, defined by IS03448:1992.

"Viscosity Index" (VI) indicates the temperature dependence of a lubricant, as measured by ASTM D2270-10 (E2011), usually performed using commercially available petroleum analysis equipment.

"Micro Carbon Residue" (MCRT) means the amount of carbon residue formed as determined by ASTM D4530, usually performed using commercially available petroleum analysis equipment.

"Aromatics extraction" is part of the process used to produce solvent neutral base oils. During aromatics extraction, solvents are used in solvent extraction units to extract vacuum gas oil, deasphalted oil or mixtures thereof. Aromatic extraction produces a waxy raffinate and an aromatic extract after solvent evaporation.

An "atmospheric resid" or "atmospheric resid" (AR) is the product of the distillation of crude oil at atmospheric pressure in which volatile materials have been removed during the distillation. AR cuts are typically produced at cut points of 650°F up to 680°F.

"Vacuum Gas Oil" (VGO) is a by-product of vacuum distillation of crude oil, which can be sent to a hydrogenation unit or an aromatics extraction unit to be upgraded to base oil. VGO typically contains hydrocarbons with a boiling range distribution between 343°C (649°F) and 538°C (1000°F) at 0.101 MPa. As used herein, the term "medium vacuum gas oil" abbreviated "MVGO" refers to vacuum gas oil or a portion thereof, including, for example, where the MVGO series has a front cut point of about 700°F or higher and a back end cut point of Vacuum gas oil of about 900°F or less, or a portion thereof. The term "heavy vacuum gas oil" abbreviated "HVGO" refers to heavy vacuum gas oil or a fraction thereof, including, for example, fractions derived from VGO. In some cases, HVGO can be derived from a VGO feedstock, where cut portions of MVGO have been separated from the VGO feedstock, leaving the remainder as HVGO fractions. For example, heavy vacuum gas oil (HVGO) may be the remainder obtained from a VGO feedstock in which the MVGO portion has been removed, the MVGO portion having a front cut point of about 700°F or higher and about 900°F or lower back-end fractionation point.

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

When used in conjunction with oil feedstocks, the terms "treated," "processed," "upgraded," "upgraded," and "upgraded" describe feedstocks that are or have been subjected to hydrogenation, or resulting materials or crude products that: The molecular weight of the feedstock is reduced, the boiling point range of the feedstock is reduced, the concentration of asphaltenes is reduced, the concentration of hydrocarbon radicals is reduced, and/or the amount of impurities such as sulfur, nitrogen, oxygen, halides, and metals is reduced.

"Solvent dewaxing" is the process of dewaxing paraffin wax by crystallization at low temperature and separation by filtration. Solvent dewaxing produces dewaxed oil and pine wax. Dewaxed oils can be further hydrorefined to produce base oils.

"Hydrogenation" refers to the process of contacting a carbonaceous feedstock with hydrogen and a catalyst at elevated temperatures and pressures to remove undesired impurities and/or convert the feedstock to desired products. Examples of hydrogenation procedures include hydrocracking, hydrotreating, catalytic dewaxing, and hydrofinishing.

"Hydrocracking" means the process of hydrogenation and dehydrogenation with cracking/fragmentation of hydrocarbons, e.g. conversion of heavier hydrocarbons to lighter hydrocarbons, or conversion of aromatics and/or naphthenes (naphthenes) to non- Cyclic branched alkanes.

"Hydroprocessing" means the process of converting a sulfur and/or nitrogen containing hydrocarbon feedstock into a hydrocarbon product with reduced sulfur and/or nitrogen content, usually in combination with hydrocracking, and which produces hydrogen sulfide and/or Ammonia (respectively) as a by-product.

"Catalytic dewaxing" or hydroisomerization refers to the process by which n-alkanes are isomerized to their more branched counterparts in the presence of hydrogen and over a catalyst.

"Hydrofinishing" means a procedure intended to improve the oxidation stability, UV stability, and appearance of hydrofinishing products by removing traces of aromatics, olefins, color bodies, and solvents. As used in this disclosure, the term UV stability refers to the stability of the tested hydrocarbon when exposed to UV light and oxygen. Instability is indicated when a visible precipitate forms, usually seen as Hoc or cloudy, or develops a darker color upon exposure to UV light and air. A general description of hydrofinishing can be found in US Patent Nos. 3,852,207 and 4,673,487.

The term "hydrogen" or "hydrogen gas" refers to hydrogen itself, and/or one or more compounds that provide a source of hydrogen.

"Cut point" refers to the temperature on the true boiling point (TBP) curve at which a predetermined degree of separation is achieved.

"TBP" means the boiling point of a hydrocarbon-containing feed or product, as determined by simulated distillation (SimDist) according to ASTM D2887-13.

"Hydrocarbon-containing", "hydrocarbon" and similar terms refer to compounds containing only carbon and hydrogen atoms. Other identifiers can be used to indicate the presence, if any, of a particular group in the hydrocarbon (eg, a halohydrocarbon indicates the presence of one or more halogen atoms in place of an equivalent number of hydrogen atoms in the hydrocarbon).

"Group IIB" or "Group IIB metal" means zinc (Zn), cadmium (Cd), mercury (Hg), and combinations thereof in elemental, compound, or ionic form.

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

"Group V metal" means vanadium (V), niobium (Nb), tantalum (Ta), and combinations thereof in elemental, compound, or ion form.

"Group VIB" or "Group VIB metal" means chromium (Cr), molybdenum (Mo), tungsten (W), and combinations thereof in elemental, compound, or ion form.

"Group VIII" or "Group VIII metal" means iron (Fe), cobalt (Co), nickel (Ni), ruthenium (Ru), rhenium (Rh), rhodium (Ro ), palladium (Pd), osmium (Os), iridium (Ir), platinum (Pt), and combinations thereof.

The term "support", especially when used in the term "catalyst support", refers to a conventional material, usually a solid with a high surface area, to which the catalyst material is attached. Support materials can be inert or participate in catalytic reactions, and can be porous or non-porous. Typical catalyst supports include various carbons, alumina, silica and silica-alumina, such as amorphous aluminosilicates, zeolites, alumina-boria, silica-alumina-magnesia, silica-alumina Alumina-titania and materials obtained by adding other zeolites and other composite oxides.

"Molecular sieve" means a material having uniform pores of molecular size within a framework structure such that, depending on the type of molecular sieve, only certain molecules have access to the pore structure of the molecular sieve to the exclusion of others, for example, 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, of which W220: refers to waxy medium base oil products with a viscosity of about 6 cSt at 100°C, W600: refers to the viscosity A waxy heavy base oil product of about 12 cSt at 100°C. After dewaxing, the typical test data of Group II base oil are as follows: nature standard test 220N 600N API base oil category (API 1509 E.1.3) Class II Class II API proportion ASTM D1298 32.1 31.0 Specific gravity at 60/60℉ ASTM D1298 0.865 0.871 Density, lb/gal ASTM D1298 7.202 7.251 Kinematic viscosity cSt at 40°C cSt at 100°C ASTM D445 41.0 6.3 106 12.0 Viscosity at 100℉, Saybolt SUS ASTM D2161 212 530 viscosity index ASTM D2270 102 102 Pour point, °C ASTM D97 -15 -15 Evaporation loss, NOACK, wt% CEC-L-40-A-93 11 2 Flash point, COC, °C ASTM D92 230 265 color ASTM D1500 L 0.5 L 0.5 Sulfur, ppm Chevron <6 <6 water, ppm ASTM D1744 <50 <50 Saturated hydrocarbons, HPLC, % by weight Chevron >99 >99 Aromatics, HPLC, % by weight Chevron <1 <1

In this disclosure, although compositions and methods or processes are generally described as "comprising" various components or steps, unless otherwise stated, compositions and methods can also "consist essentially of" various components or steps or "composed of various components or steps".

The terms "a", "an" and "the" are intended to include a plurality of alternatives, eg at least one. For example, unless otherwise specified, a disclosure of "transition metal" or "alkali metal" is intended to encompass one transition metal or alkali metal, or a mixture or combination of more than one transition metal or alkali metal.

All numerical values in the embodiments and claims herein are modified by the value indicated by "about" or "approximately", and take into account experimental error and variations that would normally be expected by those skilled in the art.

In one aspect, the invention is a process for making a base oil, the process for making a heavy base oil having a viscosity of at least about 13 cSt at 100°C, the process comprising: using, under hydrocracking conditions, contacting a base oil feed stream comprising an atmospheric resid feedstock and optionally a base oil feedstock with a hydrocracking catalyst to form a hydrocracked product; separating the hydrocracked product into a gas fraction and a liquid fraction; contacting the liquid fraction with a dewaxing catalyst under isomerization conditions to produce a dewaxed product; and optionally contacting the dewaxed product with a hydrofinishing catalyst under hydrofinishing conditions to produce a hydrofinishing dewaxed product ; wherein the process produces at least one base oil product comprising a heavy base oil product having a viscosity of at least about 13 cSt at 100°C.

The base oil raw material usually meets one or more of the following property conditions: the API gravity is in the range of 15-40 or 15-30 or 15-25, or at least 15 or at least 17, which is less than the atmospheric residual oil as the case may be Raw material; VI is in the range of 30-90 or 40-90 or 50-90 or 50-80, depending on the situation is less than the VI of the atmospheric residual oil raw material; the viscosity at 100°C is 3-30 cSt or 3-25 cSt Or in the range of 3-20 cSt, or at least 3 cSt or at least 4 cSt; the viscosity at 70°C is in the range of 5-50 cSt or 5-80% by weight or 5-70% by weight or 5-60% by weight or 5- 50% by weight or 5-40% by weight or 5-30% by weight or 5-20 cSt or 5-15 cSt in the range, or at least 5 cSt or at least ₆ cSt; hot C Asphaltene content in 0.01-0.3% by weight Or within the range of 0.01-0.2% by weight or 0.02-0.15% by weight, or less than 0.3% by weight or less than 0.2% by weight; the wax content is 5-90% by weight or 5-80% by weight or 5-70% by weight or 5- 60% by weight or 5-50% by weight or 5-40% by weight or 5-30% by weight or 10-25% by weight, or at least 5% by weight or at least 10% by weight or at least 15% by weight, or depending on The situation is less than the wax content of the atmospheric residual oil raw material; the nitrogen content is less than 2500 ppm or less than 2000 ppm or less than 1500 ppm or less than 1000 ppm, or at 1000-5000 ppm or 2000-5000 ppm or 1000-4000 ppm or 1000-3000 Within the range of ppm; sulfur content less than 40000 ppm or less than 35000 ppm or less than 30000 ppm or less than 25000 ppm or less than 20000 ppm or less than 15000 ppm or less than 10000 ppm, or in the range of 1000-40000 ppm or 1000-35000 ppm or 1000-30000 ppm or in the range of 1000-25000 ppm or 1000-15000 ppm or 1000-10000 ppm; and/or 1050+°F content of less than 10% by weight or less than 8% by weight or less than 7% by weight or less than 6% by weight or less than 5% by weight % or less than 4% by weight or less than 3% by weight or less than 2% by weight, or in the range of 2-15% by weight or 2-10% by weight or 1-7% by weight, as the case may be less than the 1050+℉ content.

In some aspects, the base stock has a nitrogen content of less than 2500 ppm, or less than 2000 ppm, or less than 1500 ppm, or less than 1000 ppm, or between 1000-5000 ppm, or 2000-5000 ppm, or 1000-4000 ppm, or In the range of 1000-3000 ppm; or with a sulfur content of less than 40000 ppm or less than 35000 ppm or less than 30000 ppm or less than 25000 ppm or less than 20000 ppm or less than 15000 ppm or less than 10000 ppm, or in the range of 1000-40000 ppm or 1000-35000 ppm or within the range of 1000-30000 ppm or 1000-25000 ppm or 1000-15000 ppm or 1000-10000 ppm; or 1050+℉ content of less than 10% by weight or less than 8% by weight or less than 7% by weight or less than 6% by weight or less 5% by weight or less than 4% by weight or less than 3% by weight or less than 2% by weight, or in the range of 2-15% by weight or 2-10% by weight or 1-7% by weight, as the case may be less than the atmospheric residual oil 1050+℉ content of raw materials; or a combination thereof.

Suitable base oil feedstocks may be derived from any crude feedstock or fractions thereof, including hydrogenated midstream or other feedstocks. Typically, base oil stocks contain materials boiling in the base oil range. Feedstocks may include atmospheric and vacuum resids from a variety of sources, including whole crude oils and paraffinic crude oils.

Atmospheric residual oil (AR) raw materials usually meet one or more of the following property conditions: API of the base oil stock; VI in the range of 50-200 or 70-190 or 90-180, or at least 80, or as the case may be greater than the VI of the base oil stock; viscosity at 100°C of 3-30 cSt or in the range of 3-25 cSt or 3-20 cSt or 3-10 cSt, or at least 3 cSt or at least 4 cSt, or less than 10 cSt; the viscosity at 70°C is in the range of 5-50 cSt or 5-30 cSt or In the range of 5-20 cSt, or 5-15 cSt, or at least 5 cSt, or at least ₆ cSt; thermal C asphaltene content in the range of about 0.01-0.3 wt%, or about 0.01-0.2 wt%, or about 0.02-0.15 wt% or less than about 0.3% by weight or less than about 0.2% by weight or less than about 0.1% by weight; the wax content is 5-90% by weight or 5-80% by weight or 5-70% by weight or 5-60% by weight or In the range of 5-50 wt. % or 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. Wax content of oil raw materials; 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 800 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 3000 ppm or less than 2000 ppm or less than 1000 ppm or less than 500 ppm or less than 200 ppm, or at 100-8000 ppm or 100-6000 ppm or 100-4000 ppm or 100-2000 ppm or 100-1000 ppm or in the range of 100-500 ppm or 100-200 ppm; and/or 1050+°F content in 2-50 wt%, 2-40 wt% or 4-50 wt% or 4-40 wt% or 8-50 wt% % or in the range of 8-40% by weight, or at most 50% by weight, or at most 40% by weight, or at most 30% by weight, or at most 20% by weight, or at most 10% by weight, as the case may be greater than the base oil stock 1050+℉ content.

In some aspects, AR feedstocks having the property profiles described herein may be advantageously derived from light tight oil (LTO, eg, shale oil with an API typically >45). Suitable feedstocks may be Permian Basin feedstocks and other locations including Eagle Ford, Avalon, Magellan, Buckeye and the like.

Atmospheric residual (AR) feedstocks are generally different from conventional AR feedstocks. For example, AR feedstocks typically differ from conventional AR feedstocks in one or more of the aforementioned feedstock properties, and AR feedstocks useful in the present invention typically have lower values and ranges for properties. _In more specific cases, AR feedstocks have lower thermal C7 asphaltene content, nitrogen and/or sulfur content, 1050+°F content, metal content (e.g., nickel, vanadium, and/or iron content) compared to conventional AR. ) or a combination thereof.

In some cases, the atmospheric resid feedstock has a thermal C-7 asphaltene content in the range of less than about 0.3 wt. %, or less than about 0.2 wt. %, or less than about 0.1 wt. %; and a nitrogen content of less than 2500 ppm or less than 2000 ppm or less than 1500 ppm or less than 1000 ppm or less than 800 ppm or less than 500 ppm or less than 200 ppm or less than 100 ppm. The atmospheric resid feedstock may also have each of the following: a thermal C-7 asphaltene content in the range of less than about 0.3 wt. % or less than about 0.2 wt. % or less than about 0.1 wt. %; a nitrogen content of less than 2500 ppm or less than 2000 ppm or less than 1500 ppm or less than 1000 ppm or less than 800 ppm or less than 500 ppm or less than 200 ppm or less than 100 ppm; and the metal content is less than about 5 ppm nickel or less than about 3 ppm vanadium or less than about 4 ppm iron; or a combination thereof. Furthermore, the AR feedstock may also satisfy the following conditions: Atmospheric residual oil feedstocks satisfy the following conditions: a viscosity at 100°C of less than 10 cSt, or in the range of 3-10 cSt; a thermal C-7 asphaltene content of less than about 0.1 wt. %, or in the range of about 0.01-0.1% by weight; the MCRT is less than 2% by weight; the nitrogen content is less than 800 ppm; the sulfur content is less than ppm; the nickel content is less than 5 ppm; the vanadium content is less than 3 ppm; and the iron content is less than 4 ppm.

Both the base oil feedstock and the atmospheric resid feedstock may have any of the preceding properties within any of the broad and narrow ranges described above and combinations of such ranges.

The base oil feed stream typically comprises 5-95% by weight atmospheric resid feedstock and 95-5% by weight base oil feedstock, or 10-90% by weight atmospheric resid feedstock and 90-10% by weight base oil Raw materials, or 10-80% by weight of atmospheric residual oil raw materials and 90-20% by weight of base oil raw materials, or 10-60% by weight of atmospheric residual oil raw materials and 90-40% by weight of base oil raw materials, or 10 - 50% by weight of atmospheric residual oil feedstock and 50-90% by weight of base oil feedstock, or 10-40% by weight of atmospheric pressure residual oil feedstock and 90-60% by weight of base oil feedstock, or 10-30% by weight Atmospheric residual oil raw material and 90-70% by weight of base oil raw material, or 30-60% by weight of atmospheric residual oil raw material and 70-40% by weight of base oil raw material, or 40-60% by weight of atmospheric residual Oil raw material and 60-40% by weight of base oil raw material.

In certain embodiments, the base oil feedstream is free of added whole crude feedstock, and/or free of vacuum resid feedstock, and/or free of deasphalted oil feedstock components, and/or contains only atmospheric resid Oil raw materials and base oil raw materials. While some of the specific property characteristics of base stock and AR stock may have similar or overlapping property values or ranges of values, base stock and AR stock are not identical in that typically one or more of the property characteristics will be significantly different . For example, in some cases, the atmospheric resid feedstock and the base oil feedstock differ in their respective nitrogen content, sulfur content, 1050+°F content, or combinations thereof.

While not limited to a straight run process, the process need not include recycling the liquid feedstock as part of the base oil feed stream or as either or both an atmospheric raffinate feedstock and a base oil feedstock. However, in certain embodiments, recycling of one or more intermediate streams may be used.

The base stock may comprise, consist essentially of, or consist of vacuum gas oil, including whole uncut stock and cut stock. The vacuum gas oil may be a heavy vacuum gas oil obtained from vacuum gas oil fractionated into a light fraction and a heavy fraction, wherein the heavy fraction has a cut point temperature range of about 950-1050 °F . VGO can also be a blend derived from various raw materials, and can include varying amounts of limiting boiling point range components. For example, one component of VGO derived from a particular feedstock may have a higher 1050+°F content while the other VGO component contributes a lower 1050+°F content to the VGO.

Typically, the dewaxed and/or hydrofined dewaxed products are obtained as light base oil products and heavy base oil products. Nominal viscosities at 100°C for light base oil products are typically in the range of about 3-9 cSt or 4-8 cSt or 5-7 cSt and/or nominal viscosities at 100°C for heavy base oil products Usually in the range of 13-24 cSt or 13-21 cSt or 13-18 cSt. The dewaxed product may be further separated into at least one light product with a nominal viscosity of about 6 cSt at 100°C, and/or a nominal viscosity of 13 cSt or higher at 100°C or 13-16.5 at 100°C cSt or at least one heavy product of about 13-23 cSt at 100°C, or a combination thereof.

One of the advantages associated with the process is that the yield of a heavy base oil product relative to a light base oil product can be increased by at least about 0.5 liquid compared to the same process that does not include an atmospheric resid feedstock in the lube oil feed stream. Volume % (Lvol.%), or at least about 1 Lvol.%, or at least about 2 Lvol.%, or at least about 5 Lvol.%. In some embodiments, the yield of heavy base oil product can be increased by at least about 0.5 Lvol.%, or at least about 1 Lvol. %, or at least about 2 Lvol.%, or at least about 5 Lvol.%, or at least about 10 Lvol.%, or at least about 20 Lvol.%. The total waxy yield can also be increased by at least about 0.5 Lvol.%, or at least about 1 Lvol.%, or at least about 2 Lvol.% compared to the same process excluding the atmospheric resid feedstock in the base oil feed stream. %, or at least about 5 Lvol.%.

In another aspect, the invention relates to a method for modifying a conventional or existing base oil process for producing a heavy base oil product, particularly a heavy base oil product having a viscosity of at least about 12.7 at 100°C cSt or at least about 13 cSt or at least about 13.3 cSt heavy base oil. In particular, a base oil process comprising subjecting a base oil feed stream to hydrocracking and dewaxing steps to form a dewaxed product comprising lighter and heavier products may be modified in accordance with the present invention by subjecting The base oil feedstock of the resid feedstock is subjected to the hydrocracking and dewaxing steps of the base oil process to produce dewaxed products. The dewaxed product is optionally further contacted with a hydrofinishing catalyst under hydrofinishing conditions to produce a hydrofinished dewaxed product.

The invention further relates to a process for the manufacture of a heavy base oil having a viscosity of at least about 12.7 cSt, or at least about 13 cSt, or at least about 13.3 cSt at 100°C from a base oil feed stream or a fraction thereof, the process comprising: Providing a base oil feed stream comprising an atmospheric resid feedstock and optionally a base oil feedstock; separating the base oil feed stream into a front cut point of about 700°F or higher and a back end cut point of about 900°F or Lower vacuum gas oil to form a medium vacuum gas oil MVGO fraction and a heavy vacuum gas oil HVGO fraction; contacting the HVGO fraction with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracking product; separating the hydrocracked product into a gaseous fraction and a liquid fraction; dewaxing the liquid fraction to produce a dewaxed product; and optionally hydrofinishing the dewaxed product to produce a hydrofinished dewaxed product , such that the process produces at least one heavy base oil product having a viscosity at 100°C of at least about 12.7 cSt, or at least about 13 cSt, or at least about 13.3 cSt.

Using a vacuum with a front cut point of about 700°F or higher and a back end cut point of about 900°F or lower, referred to herein as medium vacuum gas oil (MVGO), compared to the use of conventional VGO feedstocks Gas oil provides an improved waxy product yield of MVGO at a Group III or III+ viscosity of 4 cSt 100°C that is at least about 0.5 lvol.% or 1 greater than that of the same process excluding MVGO as a base oil feedstock lvol.% or 2 lvol.% or 3 lvol.% or 5 lvol.%.

The invention further relates to a process combining two process aspects, ie one of the feedstocks is used for deriving the narrow-cut MVGO fraction and the same or different feedstock is used for the atmospheric resid fraction. A combined process for the manufacture of base oils from base oil stocks or fractions thereof comprising: providing an atmospheric residue fraction from a base oil stock or fractions thereof; said base oil stock or fractions thereof and/or base oil atmospheric residues The fraction is separated into a narrow vacuum gas oil fraction with a front cut point of about 700°F or higher and a back end cut point of about 900°F or lower to form an MVGO fraction and a residual HVGO fraction; using the HVGO fraction as a first process Atmospheric residual oil feedstock to prepare dewaxed products and/or hydrofined dewaxed products; and/or use the MVGO fraction as base oil feedstock in the second process to prepare a viscosity index of 120 after dewaxing or higher dewaxed products and/or hydrofined dewaxed products, while also producing at least one heavy base oil product having a viscosity at 100°C of at least about 12.7 cSt or at least about 13 cSt or at least about 13.3 cSt.

In certain embodiments, the base oil feedstock may comprise tight oil, particularly light tight oil, or fractions thereof. Narrow vacuum gas oil cuts can also be derived from atmospheric resid fractions, including atmospheric resid fractions derived from light tight oils.

Advantageously, fractionating the AR feedstock into the MVGO fraction and the HVGO fraction provides the ability to produce Group III/III+ base oil products while still allowing the HVGO fraction to be used with conventional VGO base oil feedstocks to produce heavy grade base oil products, especially for A heavy base oil product having a viscosity at 100°C of at least about 12.7 cSt, or at least about 13 cSt, or at least about 13.3 cSt. For example, Group III/III+ products that can be produced include base oil products having a viscosity of about 4 cSt at 100°C (eg, 3-5 cSt at 100°C). In some embodiments, the use of MVGO to produce Group III/III+ base oil products results in higher yields of such products.

A diagram of a method or process according to one embodiment of the present invention is shown schematically in Figure 2a, wherein conventional base oil hydrotreating, hydrocracking, hydrodewaxing and hydrofinishing process steps, conditions and catalyst. Figure 2a shows the use of a feed blend of VGO and atmospheric residue (AR) compared to the prior art base oil process schematic shown in Figure 1, where conventional processes typically use VGO base oil feedstock. Figure 2b further illustrates the use of AR feedstock to form a medium vacuum gas oil fraction (MVGO) and a heavy VGO fraction (HVGO). Combination of VGO base oil raw materials to produce heavy base oil products.

Catalysts and associated process conditions suitable for use as hydrocracking, dewaxing, and hydrofinishing catalysts in processes and processes are described in a number of publications, including, for example, U.S. Patent Publication Nos. 3,852,207; 3,929,616; 6,156,695; 6,162,350號；6,274,530號；6,299,760號；6,566,296號；6,620,313號；6,635,599號；6,652,738號；6,758,963號；6,783,663號；6,860,987號；7,179,366號；7,229,548號；7,232,515號；7,288,182號；7,544,285號；7,615,196號；7,803,735號； 7,807,599; 7,816,298; 7,838,696; 7,910,761; 7,931,799; 7,964,524; 7,964,525; 7,964,526; 8,058,203; 10,196,575; Suitable catalysts generally include supported catalysts, ie, those catalysts comprising one or more supports as described herein and known in the art. Unsupported or bulk catalysts such as the mixed metal sulfide catalysts that may be described in US 2015/0136646 generally do not need to be used in this process.

Catalysts suitable for hydrocracking comprise, for example, materials having hydrogenation-dehydrogenation activity and supports for active cracking components. Such catalysts are described in detail in numerous patents and literature references. Exemplary cleavage component supports include silica-alumina, silica-zirconia composites, acid-treated clays, crystalline aluminosilicate zeolite molecular sieves such as zeolite A, faujasite, zeolite X, and zeolite Y, and combinations thereof . The hydrogenation-dehydrogenation component of the catalyst preferably comprises a metal selected from Group VIII metals and their compounds and Group VIB metals and their compounds. Preferred Group VIII components include cobalt and nickel, especially their oxides and sulfides. Preferred Group VIB components are oxides and sulfides of molybdenum and tungsten. Examples of hydrocracking catalysts suitable for use in the hydrocracking process step are combinations of nickel-tungsten-silica-alumina, nickel-molybdenum-silica-alumina and cobalt-molybdenum-silica-alumina. The hydrogenation and cracking activity of such catalysts and the ability to maintain high activity during long-term use depend on their composition and preparation.

Typical hydrocracking reaction conditions include, for example: Temperature: 450°F to 900°F (232°C to 482°C), such as 650°F to 850°F (343°C to 454°C); Pressure: 500 psig to 5000 psig (3.5 MPa to 34.5 MPa gauge), such as 1500 psig to 3500 psig (10.4 MPa to 24.2 MPa gauge); liquid reactant feed rate in terms of liquid hourly space velocity (LHSV): 0.1 hr ^-1 to 15 hr ^-1 (v/ v), e.g. 0.25 hr ⁻¹ to 2.5 hr ⁻¹ ; hydrogen feed rate in terms of H ₂ /hydrocarbon ratio: 500 SCF/bbl to 5000 SCF/bbl (89 to 890 m ³ _H2 / ^m3 feedstock); and/or hydrogen partial pressure: greater than 200 psig, such as 500 to 3000 psig; and hydrogen recirculation rate: greater than 500 SCF/B, such as between 1000 SCF/B and 7000 SCF/B .

Hydrodewaxing is primarily used to lower the pour point of a base oil and/or lower the cloud point of a base oil by removing wax from the base oil. Typically, dewaxing uses a catalytic process to process the wax, and the dewaxer feed is usually upgraded prior to dewaxing to increase the viscosity index, reduce aromatics and heteroatom content, and reduce low boiling points in the dewaxer feed Amount of component. Some dewaxing catalysts accomplish the waxy conversion reaction by cleaving the waxy molecules into lower molecular weight molecules. Other dewaxing processes can convert waxes contained in the hydrocarbon feed to the process by wax isomerization to produce isomerized molecules with lower pour points than their non-isomerized molecule counterparts. As used herein, isomerization encompasses the hydroisomerization procedure for the use of hydrogen in the isomerization of wax molecules under catalytic hydroisomerization conditions.

Dewaxing generally involves treating the dewaxer feedstock by hydroisomerization to convert at least normal paraffins and form isomerized products comprising isoparaffins. Suitable isomerization catalysts for use in the dewaxing step may include, but are not limited to, supported Pt and/or Pd. 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-32x, 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, SSZ-83, SSZ-86, SSZ-91, SSZ-95, SUZ-4, TNU-9, ZSM-S, ZSM-12, ZSM-22, ZSM-23, ZSM-35, ZSM-48, EMT type zeolite, FAU type zeolite, FER type zeolite, MEL type zeolite, MFI type zeolite, MTT type zeolite, MTW type Zeolites, MWW type zeolites, MRE type zeolites, TON type zeolites, other molecular sieve materials based on crystalline aluminum phosphate, such as SM-3, SM-7, SAPO-11, SAPO-31, SAPO-41, MAPO-11 and MAPO- 31. Isomerization may also involve Pt and/or Pd catalysts supported on acidic support materials such as beta or zeolite Y molecular sieves, silica, alumina, silica-alumina, and combinations thereof. Suitable isomerization catalysts are described in detail in the patent literature, see, eg, US Patent Nos. 4,859,312; 5,158,665; and 5,300,210.

Hydrodewaxing conditions generally depend on the feed used, the catalyst used, catalyst pretreatment, the desired yield, and the desired properties of the base oil. Typical conditions include the following: temperature from 500°F to 775°F (260°C to 413°C); pressure from 15 psig to 3000 psig (0.10 MPa to 20.68 MPa gauge); LHSV from 0.25 hr ⁻¹ to 20 hr ⁻¹ ; Hydrogen to feed ratio of 2000 SCF/bbl to 30,000 SCF/bbl (356 to 5340 m ³ H ₂ /m ³ feed). Typically, hydrogen will be separated from the product and recycled to the isomerization zone. Suitable dewaxing conditions and procedures are described, for example, in US Patent Nos. 5,135,638, 5,282,958, and 7,282,134.

Waxy products W220 and W600 can be dewaxed to form 220N and 600N neutral products which can be suitable (or more suitable) for use as lubricating base oils or in lubricant formulations. For example, dewaxed products can be mixed or blended with existing lubricating base stocks in order to create new base stocks or modify the properties of existing base stocks, for example, to meet specific target conditions for specific base stock grades such as 220N and 600N , such as viscometry or Noack target conditions. Isomerization and blending can be used to adjust and maintain the pour point and cloud point of the base oil at suitable values. The n-paraffins may also be blended with other base oil components prior to catalytic isomerization, including blending the n-paraffins with the isomerization product. The lubricating base oil that can be produced in the dewaxing step can be treated in a separation step to remove light products. The lubricating base oil can be further processed by distillation, using atmospheric distillation and optionally vacuum distillation to produce a lubricating base oil.

Typical hydrotreating conditions vary over a wide range. Generally, 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 in the range of 200 psig to 3000 psig, or alternatively from about 500 psia to about 2500 psia. The hydrogen feed rate in terms of _H2 /hydrocarbon ratio is typically 500 SCF/Bbl to 5000 SCF/bbl (89 to 890 _m3H2 ^{/ m3} feedstock), usually between 1000 SCF/Bbl and 3500 SCF/Bbl between. The reaction temperature in the reactor is typically in the range of about 300°F to about 750°F (about 150°C to about 400°C), or alternatively in the range of 450°F to 725°F (230°C to 385°C).

In practice, layered catalyst systems can be used which include hydrotreating (HDT, HDM, DEMET, etc.), hydrocracking (HCR), hydrodewaxing (HDW) and hydrofinishing (HFN ) catalysts to produce intermediate and/or finished base oils using single or multiple reactor systems. A typical configuration includes two reactors, the first containing a layered catalyst that provides DEMET, HDT pretreatment, HCR and/or HDW activity. Different catalysts performing similar functions, eg different levels of hydrocracking activity, may also be used eg in different layers within a single reactor or in multiple separate reactors.

For the avoidance of doubt, this application is concerned with the subject matter described in the following numbered paragraphs: 1. A process for making a base oil having a viscosity at 100°C of at least about 12.7 cSt or at least about 13 cSt or a heavy base oil of at least about 13.3 cSt, the process comprising contacting a base oil feed stream comprising an atmospheric resid feedstock and optionally a base oil feedstock with a hydrocracking catalyst under hydrocracking conditions to form a 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, under hydrofinishing conditions contacting the dewaxed product with a hydrofinishing catalyst to produce a hydrofinished dewaxed product; wherein the process produces at least one base oil product comprising a viscosity at 100°C of at least about 12.7 cSt or A heavy base oil product of at least about 13 cSt or at least about 13.3 cSt. 2. The method of paragraph 1 for modifying a base oil process for producing a heavy base oil having a viscosity at 100°C of at least about 12.7 cSt, or at least about 13 cSt, or at least about 13.3 cSt, wherein the base oil The process comprises subjecting a base oil feed stream to hydrocracking and dewaxing steps to form a dewaxed product comprising light products and heavy products; the process comprises, subjecting the base oil feed stream comprising the atmospheric resid feedstock Subjecting the base oil processing to the hydrocracking and dewaxing steps; wherein the modified base oil processing comprises: subjecting a base oil feedstream comprising an atmospheric resid feedstock and optionally a base oil feedstock to hydrocracking conditions contacting a hydrocracking catalyst to form a hydrocracking product; separating the hydrocracking 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 dewaxing and, optionally, contacting the dewaxed product with a hydrofinishing catalyst under hydrofinishing conditions to produce a hydrofinished dewaxed product; wherein the modified process produces at least one base oil product, the at least one base oil The product has a viscosity at 100°C of at least about 12.7 cSt, or at least about 13 cSt, or at least about 13.3 cSt. 3. A process according to paragraph 1 for the manufacture of a heavy base oil having a viscosity at 100°C of at least about 12.7 cSt, or at least about 13 cSt, or at least about 13.3 cSt from a base oil feed stream or a fraction thereof, the process comprising providing a base oil feed stream comprising an atmospheric resid feedstock and, optionally, a base oil feedstock; A vacuum gas oil fraction of 900°F or lower to form a medium vacuum gas oil MVGO fraction and a heavy vacuum gas oil HVGO fraction; and using the HVGO fraction as the atmospheric resid feedstock in the process of paragraph 1. 4. The process of any of paragraphs 1 to 3, wherein the base oil feed stream comprises a base oil feedstock. 5. The process of any one of paragraphs 1 to 4, wherein the atmospheric residual oil feedstock satisfies one or more of the following conditions: API specific gravity is in the range of 20-60 or 20-45 or 25-45, or is at least 20 or at least 22, or optionally greater than the API of the base oil stock; VI is in the range of 50-200 or 70-190 or 90-180, or is at least 80, or optionally greater than the VI of the base oil stock ; Viscosity at 100°C in the range of 3-30 cSt, or 3-25 cSt, or 3-20 cSt, or 3-10 cSt, or at least 3 cSt, or at least 4 cSt, or less than 10 cSt; Viscosity at 70°C In the range of 5-50 cSt, or 5-30 cSt, or 5-20 cSt, or 5-15 cSt, or at least 5 cSt, or at least ₆ cSt; hot C7 asphaltenes content in the range of about 0.01-0.3 wt%, or about 0.01 - 0.2% by weight or about 0.02-0.15% by weight or less than about 0.3% by weight or less than about 0.2% by weight or less than about 0.1% by weight; wax content in the range of 5-90% by weight or 5-80% by weight or 5- 70% by weight or 5-60% by weight or 5-50% by weight or 5-40% by weight or 5-30% by weight or 10-25% by weight, or at least 5% by weight or at least 10% by weight or at least 15% by weight, or greater than the wax content of the base oil stock as the case may be; 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 800 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 3000 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 in the range of 100-2000 ppm or 100-1000 ppm or 100-500 ppm or 100-200 ppm; and/or 1050+℉ content in 2-50 wt%, 2-40 wt% or 4-50 wt% or In the range of 4-40% by weight or 8-50% by weight or 8-40% by weight, or up to 50% by weight or up to 40% by weight or up to 30% by weight or up to 20% by weight or up to 10% by weight, as the case may be Greater than the 1050+°F content of the base oil stock. 6. The process of any of paragraphs 1 to ₅ , wherein the atmospheric resid feedstock has a hot C7 asphaltene content of less than about 0.3 wt % or less than about 0.2 wt % or less than about 0.1 wt % range, and the nitrogen content is less than 2500 ppm or less than 2000 ppm or less than 1500 ppm or less than 1000 ppm or less than 800 ppm or less than 500 ppm or less than 200 ppm or less than 100 ppm. 7. The process of any of paragraphs 1 to ₆ , wherein the atmospheric resid feedstock has a hot C7 asphaltene content of less than about 0.3 wt % or less than about 0.2 wt % or less than about 0.1 wt % the nitrogen content is less than 2500 ppm or less than 2000 ppm or less than 1500 ppm or less than 1000 ppm or less than 800 ppm or less than 500 ppm or less than 200 ppm or less than 100 ppm; and the metal content is less than about 5 ppm nickel or less about 3 ppm vanadium or less than about 4 ppm iron; or a combination thereof. 8. The process of any one of paragraphs 1 to 7, wherein the atmospheric residual oil feedstock satisfies the following conditions: a viscosity at 100°C of less than 10 cSt, or in the range of 3-10 cSt _; a content of hot C7 asphaltenes of less than about 0.1 wt%, or in the range of about 0.01-0.1 wt%; MCRT less than 2 wt%; nitrogen content less than 800 ppm; sulfur content less than 3000 ppm; nickel content less than 5 ppm; vanadium content less than 3 ppm; 4 ppm. 9. The process according to any one of paragraphs 1 to 8, wherein the base oil raw material satisfies one or more of the following conditions: API specific gravity is in the range of 15-40 or 15-30 or 15-25, or is at least 15 or at least 17, depending on the circumstances, less than the atmospheric residual oil feedstock; VI within the range of 30-90 or 40-90 or 50-90 or 50-80, depending on the circumstances, less than the VI of the atmospheric residual oil feedstock; 100°C The viscosity at 70°C is in the range of 3-30 cSt or 3-25 cSt or 3-20 cSt, or at least 3 cSt or at least 4 cSt; the viscosity at 70°C is in the range of 5-50 cSt or 5-80% by weight or 5 - in the range of 70% by weight or 5-60% by weight or 5-50% by weight or 5-40% by weight or 5-30% by weight 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 % or less than 0.2 wt %; wax content in the range of 5-90 wt % or 5 - in the range of 80% by weight or 5-70% by weight or 5-60% by weight or 5-50% by weight or 5-40% by weight or 5-30% by weight or 10-25% by weight, or at least 5% by weight or at least 10% by weight or at least 15% by weight, or less than the wax content of the atmospheric resid feedstock as the case may be; nitrogen content of less than 2500 ppm or less than 2000 ppm or less than 1500 ppm or less than 1000 ppm, or in the range of 1000-5000 ppm or In the range of 2000-5000 ppm or 1000-4000 ppm or 1000-3000 ppm; sulfur content is less than 40000 ppm or less than 35000 ppm or less than 30000 ppm or less than 25000 ppm or less than 20000 ppm or less than 15000 ppm or less than 10000 ppm, or in 1000-40000 ppm or 1000-35000 ppm or 1000-30000 ppm or 1000-25000 ppm or 1000-15000 ppm or 1000-10000 ppm; and/or 1050+°F content of less than 10% by weight or less than 8% by weight or Less than 7% by weight or less than 6% by weight or less than 5% by weight or less than 4% by weight or less than 3% by weight or less than 2% by weight, or at 2-15% by weight or 2-10% by weight or 1-7% by weight Within the range, it may be less than the 1050+℉ content of the atmospheric residual oil raw material as the case may be. 10. The process of any one of paragraphs 1 to 9, wherein the base oil stock has a nitrogen content of less than 2500 ppm or less than 2000 ppm or less than 1500 ppm or less than 1000 ppm, or between 1000-5000 ppm or 2000 -5000 ppm or 1000-4000 ppm or 1000-3000 ppm; or less than 40000 ppm or less than 35000 ppm or less than 30000 ppm or less than 25000 ppm or less than 20000 ppm or less than 15000 ppm or less than 10000 ppm, or in In the range of 1000-40000 ppm or 1000-35000 ppm or 1000-30000 ppm or 1000-25000 ppm or 1000-15000 ppm or 1000-10000 ppm; % by weight or less than 6% by weight or less than 5% by weight or less than 4% by weight or less than 3% by weight or less than 2% by weight, or in the range of 2-15% by weight or 2-10% by weight or 1-7% by weight , optionally less than the 1050+°F content of the atmospheric residual oil feedstock, or a combination thereof. 11. The process of any one of paragraphs 1 to 10, wherein the base oil feed stream comprises 5-95% by weight of atmospheric resid feedstock and 95-5% by weight of base oil feedstock, or 10-90% by weight Atmospheric residual oil raw material and 90-10% by weight of base oil raw material, or 10-80% by weight of atmospheric residual oil raw material and 90-20% by weight of base oil raw material, or 10-60% by weight of atmospheric residual Oil raw material and 90-40% by weight of base oil raw material, or 10-50% by weight of atmospheric residual oil raw material and 50-90% by weight of base oil raw material, or 10-40% by weight of atmospheric residual oil raw material and 90% by weight - 60% by weight of base oil stock, or 10-30% by weight of atmospheric residual oil stock and 90-70% by weight of base oil stock, or 30-60% by weight of atmospheric residual oil stock and 70-40% by weight base oil raw material, or 40-60% by weight of atmospheric residual oil raw material and 60-40% by weight of base oil raw material. 12. The process of any one of paragraphs 1 to 11, wherein the base oil feed stream does not contain added whole crude oil feedstock, or wherein the base oil feed stream does not contain vacuum resid feedstock, or wherein the base oil feed The stream is free of deasphalted oil, or wherein the base oil feed stream contains only atmospheric resid feedstock and optionally base oil feedstock. 13. The process of any of paragraphs 1 to 12, wherein the process does not include recycling liquid feedstock as part of the base oil feed stream or as either the atmospheric resid feedstock or the base oil feedstock one or both. 14. The process of any of paragraphs 1 to 13, wherein the atmospheric resid feedstock is different from the base oil feedstock. 15. The process of paragraph 14, wherein the atmospheric resid feedstock differs from the base oil feedstock in nitrogen content, sulfur content, 1050+°F content, or a combination thereof. 16. The process of any one of paragraphs 1 to 15, wherein the base oil feedstock comprises or is vacuum gas oil, or consists essentially of, or consists of vacuum gas oil. 17. The process of any one of paragraphs 1 to 16, wherein the vacuum gas oil is a heavy vacuum gas oil obtained from vacuum gas oil fractionated into a light fraction and a heavy fraction, wherein the heavy fraction The temperature range of the distillation point is about 950-1050 ℉ . 18. The process of any one of paragraphs 1 to 17, wherein the dewaxed product and/or the hydrorefined dewaxed product are obtained as a light base oil product and a heavy base oil product. 19. The process of paragraph 18, wherein the light base oil product has a nominal viscosity at 100°C in the range of 3-9 cSt or 4-8 cSt or 5-7 cSt, and/or the heavy base oil The nominal viscosity of the product at 100°C is in the range of 13-24 cSt or 13-21 cSt or 13-18 cSt. 20. The process of paragraph 18, wherein the yield of the heavy base oil product relative to the light base oil product is increased as compared to the same process without the atmospheric resid feedstock in the base oil feed stream At least about 0.5 Lvol.%, or at least about 1 Lvol.%, or at least about 2 Lvol.%, or at least about 5 Lvol.%. 21. The process of any of paragraph 18, wherein the total waxy base oil yield is increased by at least about 0.5 Lvol.% as compared to the same process without the atmospheric resid feedstock in the base oil feed stream Or at least about 1 Lvol.%, or at least about 2 Lvol.%, or at least about 5 Lvol.%. 22. The process of any one of paragraphs 1 to 21, wherein the dewaxed product is further separated into at least one lighter product or at least one heavier product or a combination thereof, the at least one lighter product having a nominal viscosity between 100 The at least one heavier product has a nominal viscosity of 13 cSt or greater at 100°C or 13-16.5 cSt at 100°C or 18- 23 cSt. 23. The process of paragraph 3, the process further comprising contacting the MVGO fraction with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracking product; separating the hydrocracking product into a gaseous fraction and a liquid fraction; The liquid fraction is contacted with a dewaxing catalyst under hydroisomerization conditions to produce a dewaxed product; and optionally, the dewaxed product is contacted with a hydrofinishing catalyst under hydrofinishing conditions to produce a hydrofinishing A dewaxed product; wherein the dewaxed product and/or the hydrorefined dewaxed product comprises a Group III or Group III+ base oil product having a viscosity index of 120 or higher after dewaxing. 24. The process of paragraph 23, wherein the dewaxed product and/or the hydrofined dewaxed product comprises a viscosity index after dewaxing of 130 or higher or a viscosity index after dewaxing of 135 or higher or a viscosity index after dewaxing Group III or Group III+ base oil products with a post-wax viscosity index of 140 or higher. 25. The process of paragraph 23, wherein the dewaxed product and/or the hydrofined dewaxed product comprises a Group III or Group III+ base oil product. 26. The process of paragraph 23, wherein the hydrocracked product has a viscosity index of at least about 135 or 140 or 145 or 150. 27. The process of any of paragraphs 1 to 26, wherein the base oil feedstock comprises tight oil or a fraction thereof, and/or the atmospheric resid feedstock is derived from a tight oil or a fraction thereof. 28. A Group II base oil product having a nominal viscosity at 100°C in the range of 13-16.5 cSt. 29. The Group II base oil product of paragraph 22, wherein the product is a Grade 800 base oil. 30. A Group II base oil product having a nominal viscosity in the range of 18-23 cSt at 100°C. 31. The Group II base oil product of paragraph 30, wherein the product is a Grade 900 base oil. 32. The Group II base oil product according to any one of paragraphs 28 to 31, which is manufactured according to any one of the technical solutions 1 to 27. example

Samples of vacuum gas oil (VGO) and atmospheric residual oil (AR) were obtained from commercially available sources and used in the process scheme shown in Figure 2a.

The process conditions used included 0.5 hr ^-1 LHSV, reactor _H2 partial pressure of 1700-1800 psia, hydrogen feed to gas-to-oil (recycle) ratio of about 4500 scfb, and temperature in the range of 700-770+°F. reactor temperature. The temperature and other process conditions were selected to produce a light base oil target product with a VI of about 109 and a viscosity of about 6 cSt at 100°C. The heavy base oil fraction is more precisely described in each of the following examples.

The catalyst loading in each of the reactors according to Figure 2a is a conventional protocol for base oil production as described above. Catalyst configurations include layered catalyst systems comprising a layer of an alkali metal hydrodemetallization (demet) catalyst on top of a reactor catalyst bed, followed by an alkali metal hydrotreating catalyst, followed by a zeolite-containing catalyst of increasing activity. Alkali metal hydrocracking catalyst layer. Example 1 - Vacuum Gas Oil (VGO) Feedstock (Comparative Feedstock)

A sample of vacuum gas oil (VGO) feedstock from commercially available sources used to produce base oil products was obtained and analyzed as a comparative base case. According to the process configuration shown in Figure 1 and Figure 2a, VGO raw material was used in the following examples. The properties of this VGO feedstock (Sample ID 2358) are shown in Table 1. Table 1 - Properties of Vacuum Gas Oil (VGO) Feedstock Feed properties VGO property value API proportion 18 Viscosity Index, VI (D2270) 52 Viscosity, 100°C (cSt) 13.23 Viscosity, 70°C (cSt) 37.56 Thermal C7 Asphaltenes (wt%) Wax content (wt%) 7 Nitrogen content (ppm) 1620 Sulfur content (ppm) 31420 1050+ (weight%) 4.7 Simdist (℉) IBP 525 5% 707 15% 776 20% 795 30% 827 35% 841 40% 855 45% 870 50% 883 55% 897 60% 912 65% 927 70% 941 75% 957 80% 975 85% 994 90% 1016 95% 1048 99% 1099 EP 1116 Example 2 - Properties of Atmospheric Residual (AR) Feedstock

Samples of atmospheric residues (AR1 to AR5) from commercially available sources were obtained and analyzed. The properties of these AR samples used as raw material components according to the invention are shown in Table 2. Table 2 - Properties of Atmospheric Residue (AR) Feedstock Feed properties AR sample property value AR1 AR2 AR3 AR4 AR5 Sample ID 2147 2188 2361 2591 2614 API proportion 26.6 36.5 28.9 32.6 32.6 Viscosity Index, VI (D2270) 108 137 106 134 123 Viscosity, 100°C (cSt) 13.23 3.843 8.683 6.425 6.511 Viscosity, 70°C (cSt) 6.957 13.04 13.5 Thermal C7 Asphaltenes (wt%) 0.12 0.0234 0.0379 Wax content (wt%) twenty four 14 25 twenty one Nitrogen content (ppm) 808 70.7 623 340 271 Sulfur content (ppm) 5654 805 3938 2266 558 1050+℉ (wt%) 24.2 8.3 15.6 11.9 14.3 Simdist (℉) IBP 439 319 573 431 310 5% 644 477 672 589 543 15% 737 578 722 673 677 20% 766 608 741 699 717 30% 814 666 775 746 774 35% 837 691 792 767 796 40% 860 715 810 785 816 45% 884 737 828 804 836 50% 907 761 849 824 856 55% 931 785 871 845 876 60% 956 809 893 869 896 65% 984 836 918 893 919 70% 1013 865 944 920 942 75% 1045 897 976 948 971 80% 1078 932 1011 982 1003 85% 1116 974 1056 1022 1044 90% 1163 1028 1111 1070 1096 95% 1224 1103 1185 1136 1173 99% 1312 1217 1268 1230 1312 EP 1329 1250 1279 1230 1339

Table 2A provides the properties of the comparative conventional AR base oil process feedstock components. It can be noted that the AR shown in Table 2 is significantly different from the AR0 shown in Table 2A. Table 2A - Properties of Representative Conventional Atmospheric Residual (AR) Feedstocks Feed properties AR0 sample property value API proportion 10.7 Viscosity Index, VI (D2270) Viscosity, 100°C (cSt) 123.7 Viscosity, 70°C (cSt) 2030.5 Thermal C7 Asphaltenes (wt%) 9.9% Wax content (wt%) Nitrogen content (ppm) 3492 Sulfur content (ppm) 48262 Nickel (ppm) 43.7 Vanadium (ppm) 180.0 MCRT (wt%) 14.3 Example 3 - Properties of Blends of Atmospheric Residual (AR) Feedstock and Vacuum Gas Oil (VGO) Feedstock

The samples of atmospheric residual oil AR1 to AR5 of Example 2 were blended with the vacuum gas oil (VGO) feedstock of Example 1 in a weight ratio, and the blends were analyzed. The properties of these AR/VGO blend samples used as illustrative feedstock according to the invention are shown in Table 3. Table 3 - Properties of Atmospheric Residual Oil (AR) and Vacuum Gas Oil (VGO) Feedstock Blends Feed properties AR/VGO blend ( w / w ) sample property values 45% AR1/ 55% VGO 50% AR2/ 50% VGO 53% AR3/ 47% VGO 20% AR4/ 80% VGO 20% AR5/ 80% VGO 50% AR4/ 50% VGO Sample ID 2148 2190 2394 3924 4122 7200 API proportion 20.9 25.9 19.9 19.9 20.6 24.3 Viscosity Index, VI (D2270) 73 100 63 72 69 97 Viscosity, 100°C (cSt) 13.68 6.912 11.99 11.63 11.12 8.783 Viscosity, 70°C (cSt) 37.28 15.21 32.4 30.59 29.12 20.45 Thermal C7 Asphaltenes (wt%) 0.0386 Wax content (wt%) 18 8 15 Nitrogen content (ppm) 1540 1050 1460 1230 1270 991 Sulfur content (ppm) 20490 15630 26160 26620 25880 17430 1050+ (weight%) 6.4 6 6.8 7.3 9.3 Simdist (℉) IBP 633 383 603 568 504 517 5% 702 551 696 693 676 633 10% 750 622 736 737 729 689 15% 781 674 763 765 761 724 20% 804 716 785 786 784 753 25% 823 750 802 804 801 775 30% 840 778 819 820 818 794 35% 856 802 834 835 833 812 40% 871 823 849 850 848 829 45% 885 841 864 865 864 847 50% 899 860 878 880 879 864 55% 915 877 893 895 894 882 60% 930 894 908 910 910 899 65% 944 912 925 927 926 919 70% 960 929 940 942 942 938 75% 978 947 958 960 960 959 80% 999 969 977 979 980 983 85% 1023 992 998 1000 1002 1009 90% 1058 1021 1023 1027 1030 1044 95% 1132 1064 1059 1066 1075 1101 99% 1293 1172 1136 1166 1246 1234 EP 1327 1216 1170 1204 1313 1267 Example 4 - Evaluation of Heavy Base Oil Production from Blends of Atmospheric Residual (AR) Feedstock and Vacuum Gas Oil (VGO) Feedstock - AR1/VGO Blend

A blend feedstock sample of Atmospheric Resid AR1 and Vacuum Gas Oil (VGO) of Example 3 was evaluated for heavy base oil production according to the process represented by Figure 2a. The full liquid product of the AR1/VGO feedstock blend (45 wt% AR1, 55 wt% VGO) was distilled into eight fractions, the heaviest of which had a 911°F cut point. Distillation models show that 40,000 BPOD of the full liquid product fed to the hydrocracker can be distilled into the following products: 14,460 BPOD of waxy heavy neutral base oil product (17.05 cSt at 100°C, VI of 114, 898°F+), Corresponding to 36.2% by weight of product; 13,010 BPOD Waxy 220 neutral base oil product (6.0 cSt at 100°C, VI of 108.754-898°F), corresponding to 32.5% by weight of product; and 27,470 BPOD total waxy The base oil product, 754°F+ oil, corresponds to 68.7% by weight of the liquid product. Example 5 - Evaluation of Heavy Base Oil Production from Blends of Atmospheric Residual (AR) Feedstock and Vacuum Gas Oil (VGO) Feedstock - AR2/VGO Blend

A blend feedstock sample of atmospheric resid AR2 and vacuum gas oil (VGO) of Example 3 was evaluated for heavy base oil production according to the process represented by Figure 2a.

The total amount of base oil is 56% by weight of the liquid product. The various base oils have the following properties: 34% by weight of the total liquid product is a waxy 220 neutral base oil product (6.0 cSt at 100°C, VI is 114, 750-905°F); 24% by weight of the total liquid product It is a heavy neutral base oil product (12.85 cSt at 100°C, VI of 118, 905°F+). Example 6 - Evaluation of Heavy Base Oil Production from Blends of Atmospheric Residual (AR) Feedstock and Vacuum Gas Oil (VGO) Feedstock - AR3/VGO Blend

A blend feedstock sample of atmospheric resid AR3 and vacuum gas oil (VGO) of Example 3 was evaluated for heavy base oil production according to the process represented by Figure 2a. The total amount of base oil is 56% by weight of the liquid product. The various base oils have the following properties: 34% by weight of the total liquid product is a waxy 220 neutral base oil product (6.0 cSt at 100°C, VI is 108, 750-903°F); 22% by weight of the total liquid product It is a heavy-heavy neutral base oil product (14.50 cSt at 100°C, VI of 114, 903°F+). Example 7 - Evaluation of Heavy Base Oil Production from Blends of Atmospheric Residual (AR) Feedstock and Vacuum Gas Oil (VGO) Feedstock - 50% AR4/VGO Blend

The sample ID 7200 blend feedstock of Example 3 consisting of 50% atmospheric resid AR4 and vacuum gas oil (VGO) was evaluated for heavy base oil production according to the process represented by Figure 2a. The total amount of base oil is 68% by weight of the liquid product. The various base oils have the following properties: 55% by weight of the total liquid product is a waxy 220 neutral base oil product (6.0 cSt at 100°C, VI is 118, 708-977°F); 13% by weight of the total liquid product It is a heavy neutral base oil product with high viscosity (21.12 cSt at 100°C, VI is 111, 977°F+). Example 8 - Evaluation of Heavy Base Oil Production from Comparative Feedstock Using Vacuum Gas Oil (VGO) Feedstock

A feedstock sample of vacuum gas oil (VGO) of Example 3 was evaluated for heavy base oil production according to the process represented by Figure 1 . The total amount of base oil is 48% by weight of the liquid product. Various base oils have the following properties: 27% by weight of the total liquid product is waxy 220 neutral base oil product (6.0 cSt at 100°C, VI is 109, 750-885°F); 21% by weight of the total liquid product was heavy neutral base oil product (11.61 cSt at 100°C, VI of 116,885°F+).

In the foregoing Examples 4 to 7 , the heavy neutral base oil had a higher viscosity than the heavy neutral product manufactured in Comparative Base Case Example 8 . Specifically, the heavier base oil product made from VGO alone (Example 8, base case without AR) did not meet the target viscosity of about 13 cSt at 100°C. The use of atmospheric resid as a feedstock or feedstock blend has been shown to advantageously allow the production of extra heavy grades of base oil following a full hydrogenation route. The use of AR feed components results in higher yields and higher product quality, and allows processing of feed blends with heavier components and higher endpoints. While variations in fractionation goals and conditions can result in base oil products with additional or different properties, in all cases, the use of atmospheric resid feedstocks enables the production of extra-heavy bases not normally obtainable by processing typical or standard base oil feedstocks alone Oil.

The foregoing description of one or more embodiments of the invention has been presented primarily for illustrative purposes, and it should be recognized that variations may be employed that still encompass the essence of the invention. When determining the scope of the present invention, the following technical solutions should be referred to.

For purposes of U.S. patent practice, and as permitted by other patent offices, all patents and publications cited in the preceding description of this invention are hereby incorporated by reference to the extent that any information contained therein is consistent with the prior disclosure content and/or supplement previously disclosed content.

The scope of the present invention is not limited by any representative drawings accompanying this disclosure, and should be understood as being defined by the claims of this application. Figure 1 is a general block diagram schematic of a prior art process for manufacturing base oil products. Figure 2a is a generalized block diagram schematic representation of one embodiment of a process according to the present invention for making base oils using atmospheric residual oil (AR) or a blend of vacuum gas oil (VGO) and AR (VGO/AR) . Figure 2b is a generalized block diagram schematic representation of one embodiment of a process according to the present invention for producing a Group III/III+ base oil product using a medium vacuum gas oil (MVGO) fraction from atmospheric resid and using The heavy vacuum gas oil (HVGO) residual fraction of residual oil or the blend of VGO and HVGO (VGO/HVGO) produces heavy base oil products.

Claims (32)

A process for the manufacture of base oils for heavy base oils having a viscosity at 100°C of at least about 12.7 cSt, or at least about 13 cSt, or at least about 13.3 cSt, the process comprising contacting a base oil feed stream comprising an atmospheric resid feedstock, and optionally a base oil feedstock, 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; Wherein the process produces at least one base oil product comprising a heavy base oil product having a viscosity at 100°C of at least about 12.7 cSt, or at least about 13 cSt, or at least about 13.3 cSt. The method of claim 1 for modifying a base oil process for producing a heavy base oil having a viscosity of at least about 12.7 cSt or at least about 13 cSt or at least about 13.3 cSt at 100°C, wherein the base oil process comprising subjecting a base oil feed stream to hydrocracking and dewaxing steps to form a dewaxed product comprising light products and heavy products; the process comprising, subjecting the base oil feedstream comprising the atmospheric resid feedstock to the hydrocracking step and the dewaxing step of the base oil process; Wherein the modified base oil process includes: contacting a base oil feed stream comprising an atmospheric resid feedstock, and optionally a base oil feedstock, with a hydrocracking catalyst under hydrocracking conditions to form a hydrocracked product; separating the hydrocracked product into at least a gas 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 modified process produces at least one base oil product having a viscosity at 100°C of at least about 12.7 cSt, or at least about 13 cSt, or at least about 13.3 cSt. A process for producing a heavy base oil having a viscosity at 100°C of at least about 12.7 cSt, or at least about 13 cSt, or at least about 13.3 cSt from a base oil feed stream or a fraction thereof as claimed in claim 1, the process comprising providing a base oil feed stream comprising an atmospheric resid feedstock and optionally a base oil feedstock; Separating the base oil feed stream or a fraction thereof into a vacuum gas oil fraction having a front cut point of about 700°F or higher and a back end cut point of about 900°F or lower to form a medium vacuum gas oil MVGO distillate and heavy vacuum gas oil HVGO fraction; and Use the HVGO fraction as the atmospheric residual oil raw material in the process of claim 1. The process according to any one of claims 1 to 3, wherein the base oil feed stream comprises base oil feedstock. The process of any one of claims 1 to 4, wherein the atmospheric residual oil raw material satisfies one or more of the following conditions: API specific gravity is within the range of 20-60 or 20-45 or 25-45, or is at least 20 or at least 22, or optionally greater than the API of the base oil stock; 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 stock; Viscosity at 100°C in the range of 3-30 cSt or 3-25 cSt or 3-20 cSt or 3-10 cSt, or at least 3 cSt or at least 4 cSt, or less than 10 cSt; viscosity at 70°C in the In the range of 5-50 cSt or 5-30 cSt or 5-20 cSt or 5-15 cSt, or at least 5 cSt or at least ₆ cSt; hot C Asphaltenes content in about 0.01-0.3% by weight or about 0.01- 0.2% by weight or about 0.02-0.15% by weight or less than about 0.3% by weight or less than about 0.2% by weight or less than about 0.1% by weight; wax content in the range of 5-90% by weight or 5-80% by weight or 5-70 % by weight or 5-60% by weight or 5-50% by weight or 5-40% by weight or 5-30% by weight or 10-25% by weight, or at least 5% by weight or at least 10% by weight or at least 15% by weight % by weight, or greater than the wax content of the base stock as the case may be; 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 800 ppm or less than 500 ppm or less than 200 ppm or less than 100 ppm; sulfur Content less than 8000 ppm or less than 6000 ppm or less than 4000 ppm or less than 3000 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+℉ content in 2-50% by weight, 2-40% by weight or 4-50% by weight or 4 - 40% by weight or 8-50% by weight or 8-40% by weight, or up to 50% by weight, or up to 40% by weight, or up to 30% by weight, or up to 20% by weight, or up to 10% by weight , as the case may be greater than the 1050+℉ content of the base oil raw material. The process according to any one of claims 1 to ₅ , wherein the atmospheric resid feedstock has the following: a hot C7 asphaltene content of less than about 0.3% by weight or less than about 0.2% by weight or less than about 0.1% by weight Within the range, and the nitrogen content is less than 2500 ppm or less than 2000 ppm or less than 1500 ppm or less than 1000 ppm or less than 800 ppm or less than 500 ppm or less than 200 ppm or less than 100 ppm. The process according to any one of claims 1 to ₆ , wherein the atmospheric resid feedstock has the following: a hot C7 asphaltene content of less than about 0.3% by weight or less than about 0.2% by weight or less than about 0.1% by weight Nitrogen content is less than 2500 ppm or less than 2000 ppm or less than 1500 ppm or less than 1000 ppm or less than 800 ppm or less than 500 ppm or less than 200 ppm or less than 100 ppm; and the metal content is less than about 5 ppm nickel or less than about 3 ppm vanadium or less than about 4 ppm iron; or a combination thereof. The process of any one of claims 1 to 7, wherein the atmospheric residual oil raw material satisfies the following conditions: the viscosity at 100°C is less than 10 cSt, or within the range of 3-10 cSt; the content of thermal C ₇ asphaltenes is less than About 0.1 wt%, or in the range of about 0.01-0.1 wt%; MCRT less than 2 wt%; nitrogen content less than 800 ppm; sulfur content less than 3000 ppm; nickel content less than 5 ppm; vanadium content less than 3 ppm; and iron content Less than 4 ppm. The process according to any one of claims 1 to 8, wherein the base oil raw material satisfies one or more of the following conditions: API specific gravity is in the range of 15-40 or 15-30 or 15-25, or is at least 15 Or at least 17, as the case may be, less than the atmospheric residual oil feedstock; VI within the range of 30-90 or 40-90 or 50-90 or 50-80, depending on the circumstances, less than the VI of the atmospheric residual oil feedstock; at 100°C The viscosity is in the range of 3-30 cSt or 3-25 cSt or 3-20 cSt, or is at least 3 cSt or at least 4 cSt; the viscosity at 70°C is in the range of 5-50 cSt or 5-80% by weight or 5- In the range of 70% by weight or 5-60% by weight or 5-50% by weight or 5-40% by weight or 5-30% by weight or 5-20 cSt or 5-15 cSt, or at least 5 cSt or at least 6 cSt; Thermal C _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 % or less than 0.2 wt %; wax content in the range of 5-90 wt % or 5- 80% by weight or 5-70% by weight or 5-60% by weight or 5-50% by weight or 5-40% by weight or 5-30% by weight or 10-25% by weight, or at least 5% by weight or At least 10% by weight or at least 15% by weight, or less than the wax content of the atmospheric resid feedstock as the case may be; nitrogen content of less than 2500 ppm or less than 2000 ppm or less than 1500 ppm or less than 1000 ppm, or in the range of 1000-5000 ppm or 2000 -5000 ppm or in the range of 1000-4000 ppm or 1000-3000 ppm; sulfur content of less than 40000 ppm or less than 35000 ppm or less than 30000 ppm or less than 25000 ppm or less than 20000 ppm or less than 15000 ppm or less than 10000 ppm, or in 1000 -40000 ppm or 1000-35000 ppm or 1000-30000 ppm or 1000-25000 ppm or 1000-15000 ppm or 1000-10000 ppm; and/or 1050+°F content of less than 10% by weight or less than 8% by weight or less than 7% by weight or less than 6% by weight or less than 5% by weight or less than 4% by weight or less than 3% by weight or less than 2% by weight, or in the range of 2-15% by weight or 2-10% by weight or 1-7% by weight If necessary, it may be less than the 1050+℉ content of the atmospheric residual oil raw material. The process according to any one of claims 1 to 9, wherein the base oil raw material has the following: the nitrogen content is less than 2500 ppm or less than 2000 ppm or less than 1500 ppm or less than 1000 ppm, or between 1000-5000 ppm or 2000- 5,000 ppm or within the range of 1,000-4,000 ppm or 1,000-3,000 ppm; or less than 40,000 ppm or less than 35,000 ppm or less than 30,000 ppm or less than 25,000 ppm or less than 20,000 ppm or less than 15,000 ppm or less than 10,000 ppm, or within 1,000 -40000 ppm or 1000-35000 ppm or 1000-30000 ppm or 1000-25000 ppm or 1000-15000 ppm or 1000-10000 ppm range; or 1050+°F content of less than 10% by weight or less than 8% by weight or less than 7% by weight % or less than 6% by weight or less than 5% by weight or less than 4% by weight or less than 3% by weight or less than 2% by weight, or in the range of 2-15% by weight or 2-10% by weight or 1-7% by weight, Optionally less than the 1050+°F content of the atmospheric residual oil feedstock; or a combination thereof. The process of any one of claims 1 to 10, wherein the base oil feed stream comprises 5-95% by weight of atmospheric residual oil feedstock and 95-5% by weight of base oil feedstock, or 10-90% by weight of Atmospheric residual oil raw material and 90-10% by weight of base oil raw material, or 10-80% by weight of atmospheric residual oil raw material and 90-20% by weight of base oil raw material, or 10-60% by weight of atmospheric residual oil Raw materials and 90-40% by weight of base oil raw materials, or 10-50% by weight of atmospheric residual oil raw materials and 50-90% by weight of base oil raw materials, or 10-40% by weight of atmospheric residual oil raw materials and 90- 60% by weight of base oil raw material, or 10-30% by weight of atmospheric residual oil raw material and 90-70% by weight of base oil raw material, or 30-60% by weight of atmospheric residual oil raw material and 70-40% by weight of Base oil raw material, or 40-60% by weight of atmospheric residual oil raw material and 60-40% by weight of base oil raw material. The process of any one of claims 1 to 11, wherein the base oil feed stream does not contain added whole crude feed, or wherein the base oil feed stream does not contain vacuum resid feed, or wherein the base oil feed The stream does not contain deasphalted oil, or wherein the base oil feed stream contains only atmospheric resid feedstock and optionally base oil feedstock. The process of any one of claims 1 to 12, wherein the process does not include recycling liquid feedstock as part of the base oil feed stream or as either the atmospheric resid feedstock or the base oil feedstock or both. The process according to any one of claims 1 to 13, wherein the atmospheric residual oil raw material is different from the base oil raw material. The process of claim 14, wherein the atmospheric residual oil feedstock is different from the base oil feedstock in terms of nitrogen content, sulfur content, 1050+°F content, or a combination thereof. The process according to any one of claims 1 to 15, wherein the base oil raw material comprises vacuum gas oil or is vacuum gas oil, or basically consists of vacuum gas oil, or consists of vacuum gas oil. The process according to any one of claims 1 to 16, wherein the vacuum gas oil is a heavy vacuum gas oil obtained from vacuum gas oil fractionated into light fractions and heavy fractions, wherein the heavy fraction is The cut point temperature range is about 950-1050°F. The process according to any one of claims 1 to 17, wherein the dewaxed product and/or the hydrorefined dewaxed product are obtained as a light base oil product and a heavy base oil product. The process of claim 18, wherein the light base oil product has a nominal viscosity at 100°C in the range of 3-9 cSt or 4-8 cSt or 5-7 cSt, and/or the heavy base oil product The nominal viscosity at 100°C is in the range of 13-24 cSt or 13-21 cSt or 13-18 cSt. The process of claim 18, wherein the yield of the heavy base oil product relative to the light base oil product is increased by at least About 0.5 Lvol.%, or at least about 1 Lvol.%, or at least about 2 Lvol.%, or at least about 5 Lvol.%. The process of any one of claim 18, wherein the total waxy base oil yield is increased by at least about 0.5 Lvol.% or At least about 1 Lvol.%, or at least about 2 Lvol.%, or at least about 5 Lvol.%. A process according to any one of claims 1 to 21, wherein the dewaxed product is further separated into at least one lighter product or at least one heavier product or a combination thereof, the at least one lighter product having a nominal viscosity at 100°C In the range of about 5.5 to 7.5 cSt, the at least one heavier product has a nominal viscosity of 13 cSt or higher at 100°C or 13-16.5 cSt at 100°C or 18-23 cSt at 100°C cSt. Such as the process of claim 3, the process further includes contacting the MVGO fraction 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; Wherein, the dewaxed product and/or the hydrorefined dewaxed product comprises a Group III or Group III+ base oil product having a viscosity index of 120 or higher after dewaxing. The process of claim 23, wherein the dewaxed product and/or the hydrorefined dewaxed product has a viscosity index of 130 or higher after dewaxing or a viscosity index of 135 or higher after dewaxing or after dewaxing Group III or Group III+ base oil products with a post-viscosity index of 140 or higher. The process according to claim 23, wherein the dewaxed product and/or the hydrorefined dewaxed product comprises Group III or Group III+ base oil products. The process of claim 23, wherein the hydrocracked product has a viscosity index of at least about 135 or 140 or 145 or 150. The process according to any one of claims 1 to 26, wherein the base oil feedstock comprises tight oil or a fraction thereof, and/or the atmospheric residual oil feedstock is derived from tight oil or a fraction thereof. A Group II base oil product having a nominal viscosity in the range of 13-16.5 cSt at 100°C. Such as the Group II base oil product of claim 22, wherein the product is grade 800 base oil. A Group II base oil product having a nominal viscosity in the range of 18-23 cSt at 100°C. Such as the Group II base oil product of claim 30, wherein the product is grade 900 base oil. The Group II base oil product according to any one of Claims 28 to 31, the Group II base oil product is produced according to any one of Claims 1 to 27.

Images