Note: Descriptions are shown in the official language in which they were submitted.
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PROCESS FOR IMPROVING BASE OIL YIELDS
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority to U.S. Provisional
Patent Appl. Ser. No.
62/885,359, filed on August 12, 2019, the disclosure of which is herein
incorporated in its entirety.
FIELD OF THE INVENTION
[0002] The invention concerns a process for improving base oil yields by
combining an
atmospheric resid feedstock with a base oil feedstock to form a combined
feedstreann and forming a
base oil product therefrom via hydroprocessing.
BACKGROUND OF THE INVENTION
[0003] High quality lubricating base oils, such as those having a viscosity
index (VI) of 120 or
greater (Group II and Group III), may generally be produced from high-boiling
point vacuum
distillates, such as vacuum gas oils (VGO), by hydrocracking to raise VI,
followed by catalytic
dewaxing to lower pour point and cloud point, and followed by hydrofinishing
to saturate aromatics
and improve stability. In hydrocracking, high-boiling molecules are cracked to
lower-boiling
molecules which raises VI but also lowers the viscosity. In order to make a
high VI and high viscosity
grade base oil at high yield, the hydrocracker feed must contain a certain
quantity of high-boiling
molecules. Typically, VG0s are limited in their ability to recover very high-
boiling molecules from
atmospheric resid (AR) in a vacuum column because of practical limits on
temperature and pressure.
One possible means of feeding higher-boiling molecules to the hydrocracker is
to feed the AR
directly, but such an approach is not normally possible or workable because
the AR usually contains
materials that are extremely harmful to the hydrocracker catalyst, including,
e.g., nickel, vanadium,
micro-carbon residue (MCR) and asphaltenes. These materials shorten the
hydrocracker catalyst life
to an unacceptable degree, making the use of such feeds impracticable.
[0004] One approach to using difficult whole crude and other intermediate
feeds for making
base oils is to first process the feed, such as AR or vacuum resid (VR), in a
solvent deasphalting (SDA)
unit. Such treatment is usually necessary to separate the bulk of undesirable
materials while
producing a deasphalted oil (DAO) of acceptable hydrocracker feed quality. The
very high capital
requirements and high operating cost of such SDA units, and the overall
process approach, make
them undesirable alternatives, however. Other approaches that attempt to
minimize or eliminate
the need for solvent deasphalting steps have been implemented but have not
provided a clear
benefit in terms of cost or other process improvements.
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[0005] The production of Group III base oils and finished motor oils has
usually required the use
of expensive and supply-limited viscosity index improvers such as
polyalphaolefins, or other
expensive processing techniques, such as the use of gas-to-liquid (GTL)
feedstocks or, e.g., through
multi-hydrocracking processing of mineral oils. The production of Group III
base oils also generally
requires high quality feedstock(s) and processing at high conversion to meet a
VI targets at the
expense of product yield. Despite continuing industry efforts, however, a
comparatively inexpensive
and suitable feedstock, and a simplified process for making such products,
remains to be developed
and commercialized.
[0006] Despite the progress in producing base oils from differing and
challenging feeds, a
continuing need exists for improved processes to both utilize different
feedstocks and to increase
the yield of valuable base oil products.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to a process for making a base oil
product, particularly
a light grade base oil product and a heavy grade base oil product through
hydroprocessing of a base
oil feedstreann. While not necessarily limited thereto, one of the goals of
the invention is to provide
increased base oil yield of a heavy grade base oil product and to the
production of Group II and/or
Group III/III+ base oils.
[0008] In general, a first process according to the invention comprises
making a base oil by
combining an atmospheric resid feedstock and a base oil feedstock to form a
base oil feedstreann;
contacting the base oil feedstreann 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
hydroisonnerization
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.
[0009] The invention also relates to a method for modifying a base oil
process through the
addition of an atmospheric resid feedstock to a base oil feedstock in a
conventional base oil process
that comprises subjecting a base oil feedstreann to hydrocracking and dewaxing
steps to form a
dewaxed product comprising a light product and a heavy product. As such, the
modified base oil
process comprises combining an atmospheric resid feedstock and a base oil
feedstock to form a base
oil feedstreann; contacting the base oil feedstreann with a hydrocracking
catalyst under
hydrocracking conditions to form a hydrocracked product; separating the
hydrocracked product into
at least a gaseous fraction and a liquid fraction; contacting the liquid
fraction with a dewaxing
catalyst under hydroisonnerization conditions, to produce a dewaxed product;
and, optionally,
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contacting the dewaxed product with a hydrofinishing catalyst under
hydrofinishing conditions to
produce a hydrofinished dewaxed product.
[0010] A second process according to the invention comprises making a base
oil having a
viscosity index of 120 or greater by contacting a base oil feedstock having a
viscosity index of
about 100 or greater that comprises a medium vacuum gas oil (MVGO) having a
front end cut
point of about 700 F or greater and a back end cut point of about 900 F or
less with a
hydrocracking catalyst under hydrocracking conditions to form a hydrocracked
product;
separating the hydrocracked product into a gaseous fraction and a liquid
fraction; dewaxing of
the liquid fraction to produce a dewaxed product; and optionally,
hydrofinishing of the dewaxed
product to produce a hydrofinished dewaxed product.
[0011] The invention further relates to a combined process for making a
base oil product
from a base oil feedstock that combines the first process and the second
process to make base
oils meeting Group II and/or Group III/III+ specifications. The combined
process generally
provides for making a base oil from a base oil feedstock, or a fraction
thereof, and includes the use
of an atmospheric resid fraction from a base oil feedstock, or a fraction
thereof; separation of the
base oil feedstock, or a fraction thereof, and/or the base oil atmospheric
resid fraction into a narrow
vacuum gas oil cut-point fraction having a front end cut point of about 700 F
or greater and a back
end cut point of about 900 F or less to form a medium vacuum gas oil (MVGO)
fraction and a
residual heavy VG0 (HHVGO) fraction; and use of the HHVGO fraction as the
atmospheric resid
feedstock in the first process; and/or use of the MVGO fraction as the base
oil feedstock in the
second process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The scope of the invention is not limited by any representative
figures accompanying
this disclosure and is to be understood to be defined by the claims of the
application.
[0013] FIG. 1 is a general block diagram schematic illustration of a prior
art process to make a
base oil product.
[0014] FIG. 2a is a general block diagram schematic illustration of an
embodiment of a process
to make a base oil product using a blend of VG0 and atmospheric resid (VGO/AR)
according to the
invention.
[0015] FIG. 2b is a general block diagram schematic illustration of an
embodiment of a process
to make a Group III/III+ base oil product using an MVGO fraction from an
atmospheric resid and a
Group II base oil product using a blend of VG0 and an HHVGO residual fraction
from an atmospheric
resid (VGO/HHVG0) according to the invention.
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[0016] FIG. 3a is a process schematic illustration of an embodiment of a
process to make a base
oil product according to the invention, as described in the examples.
[0017] FIG. 3b is a process schematic illustration of an embodiment of a
process to make a base
oil product according to the invention, as described in the examples.
[0018] FIG. 4 is a process schematic illustration of an embodiment of a
process to make a base
oil product according to the invention, as described in the examples.
[0019] FIG. 5 is a process schematic illustration of an embodiment of a
process to make a base
oil product according to the invention, as described in the examples.
DETAILED DESCRIPTION
[0020] Although illustrative embodiments of one or more aspects are
provided herein, the
disclosed processes may be implemented using any 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
modified within the scope of the appended claims along with their full scope
of equivalents.
[0021] Unless
otherwise indicated, the following terms, terminology, and definitions are
applicable to this disclosure. If a term is used in this disclosure but is not
specifically defined herein,
the definition from the IUPAC Compendium of Chemical Terminology, 2nd ed
(1997), may be
applied, provided that definition does not conflict with any other disclosure
or definition applied
herein, or render indefinite or non-enabled any claim to which that definition
is applied. 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 is to
be understood to apply.
[0022] "API Base Oil Categories" are classifications of base oils that meet
the different criteria
shown in Table 1:
Table 1: Base Oil Stock Properties (4 cSt @100 C viscosity stocks, no
additives)
P P
,) ,)
Group .,.; vi= 5: c
._ Composition a.,
>
.,., >: ¨
.,
._ >: o .g
Designation - ro v, .
)
.-
_ o x 1,7,
D D c s- -C
RS RS D v)
v) -0 TD TD 0 RS
V) CCA 5
. Distilled, solvent refined, and/or nned- -5 to
Group I - - >0.03 <90 80419 15-20 high 15
100
>10% aromatics
: Distilled, solvent refined, - and -10 to
Group II : hydrocracked, <10% - D3.03 - 80-119 10-15
- nned 170
:
......... , aromatics -------- 90 -20
Distilled, solvent refined, . and -10 to
Group III = severely hydrocracked, D0.03 - 120 5-15 -
nned 190
.
= <10% aromatics 90 25
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; Group III oils additionally
hydroisomerized, or -15 to
Group III+ ; -- J.30 low ; 200
otherwise processed, <1% -30
aromatics
Polyalphaolefins (PAO)
100% catalytically
Group IV synthesized from olefins 135-140 1.8 low -
53 : 270
derived from thermally
=
cracking wax
100% catalytically
synthesized by reacting
Group V acids and alcohols; All 140 1.0 high -21
260
base oils not included in ;
- Groups I-IV
[0023] "API gravity" refers to the gravity of a petroleum feedstock or
product relative to water,
as determined by ASTM D4052-11 or ASTM D1298.
[0024] "ISO-VG" refers to the viscosity classification that is recommended
for industrial
applications, as defined by 1503448:1992.
[0025] "Viscosity index" (VI) represents the temperature dependency of a
lubricant, as
determined by ASTM D2270-10(E2011).
[0026] "Aromatic Extraction" is part of a process used to produce solvent
neutral base oils.
During aromatic extraction, vacuum gas oil, deasphalted oil, or mixtures
thereof are extracted using
solvents in a solvent extraction unit. The aromatic extraction creates a waxy
raffinate and an
aromatic extract, after evaporation of the solvent.
[0027] "Atmospheric resid" or "atmospheric residuum" (AR) is a product of
crude oil distillation
at atmospheric pressure in which volatile material has been removed during
distillation. AR cuts are
typically derived at 650 F up to a 680 F cut point.
[0028] "Vacuum gas oil" (VGO) is a byproduct of crude oil vacuum
distillation that can be sent
to a hydroprocessing unit or to an aromatic extraction for upgrading into base
oils. VG0 generally
comprises hydrocarbons with a boiling range distribution between 343 C (649 F)
and 538 C (1000 F)
at 0.101 MPa.
[0029] "Deasphalted oil" (DA0) generally refers to the residuum from a
vacuum distillation unit
that has been deasphalted in a solvent deasphalting process. Solvent
deasphalting in a refinery is
described in J. Speight, Synthetic Fuels Handbook, ISBN 007149023X, 2008,
pages 64, 85-85, and
121.
[0030] "Treatment," "treated," "upgrade," "upgrading" and "upgraded," when
used in
conjunction with an oil feedstock, describes a feedstock that is being or has
been subjected to
hydroprocessing, or a resulting material or crude product, having a reduction
in the molecular
weight of the feedstock, a reduction in the boiling point range of the
feedstock, a reduction in the
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concentration of asphaltenes, a reduction in the concentration of hydrocarbon
free radicals, and/or
a reduction in the quantity of impurities, such as sulfur, nitrogen, oxygen,
halides, and metals.
[0031] "Solvent Dewaxing" is a process of dewaxing by crystallization of
paraffins at low
temperatures and separation by filtration. Solvent dewaxing produces a dewaxed
oil and slack wax.
The dewaxed oil can be further hydrofinished to produce base oil.
[0032] "Hydroprocessing" refers to a process in which a carbonaceous
feedstock is brought into
contact with hydrogen and a catalyst, at a higher temperature and pressure,
for the purpose of
removing undesirable impurities and/or converting the feedstock to a desired
product. Examples of
hydroprocessing processes include hydrocracking, hydrotreating, catalytic
dewaxing, and
hydrofinishing.
[0033] "Hydrocracking" refers to a process in which hydrogenation and
dehydrogenation
accompanies the cracking/fragmentation of hydrocarbons, e.g., converting
heavier hydrocarbons
into lighter hydrocarbons, or converting aromatics and/or cycloparaffins
(naphthenes) into non-
cyclic branched paraffins.
[0034] "Hydrotreating" refers to a process that converts sulfur and/or
nitrogen-containing
hydrocarbon feeds into hydrocarbon products with reduced sulfur and/or
nitrogen content, typically
in conjunction with hydrocracking, and which generates hydrogen sulfide and/or
ammonia
(respectively) as byproducts.
[0035] "Catalytic dewaxing", or hydroisonnerization, refers to a process in
which normal
paraffins are isonnerized to their more branched counterparts in the presence
of hydrogen and over
a catalyst.
[0036] "Hydrofinishing" refers to a process that is intended to improve the
oxidation stability,
UV stability, and appearance of the hydrofinished product 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 hydrocarbon being tested when exposed to UV light and oxygen. Instability
is indicated when a
visible precipitate forms, usually seen as Hoc or cloudiness, or a darker
color develops upon
exposure to ultraviolet light and air. A general description of hydrofinishing
may be found in U.S.
Patent Nos. 3,852,207 and 4,673,487.
[0037] The term "Hydrogen" or "hydrogen" refers to hydrogen itself, and/or
a compound or
compounds that provide a source of hydrogen.
[0038] "Cut point" refers to the temperature on a True Boiling Point (TBP)
curve at which a
predetermined degree of separation is reached.
[0039] "TBP" refers to the boiling point of a hydrocarbonaceous feed or
product, as determined
by Simulated Distillation (SinnDist) by ASTM D2887-13.
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[0040] "Hydrocarbonaceous", "hydrocarbon" and similar terms refer to a
compound containing
only carbon and hydrogen atoms. Other identifiers may be used to indicate the
presence of
particular groups, if any, in the hydrocarbon (e.g., halogenated hydrocarbon
indicates the presence
of one or more halogen atoms replacing an equivalent number of hydrogen atoms
in the
hydrocarbon).
[0041] "Group IIB" or "Group IIB metal" refers to zinc (Zn), cadmium (Cd),
mercury (Hg), and
combinations thereof in any of elemental, compound, or ionic form.
[0042] "Group IVA" or" "Group IVA metal" refers to germanium (Ge), tin (Sn)
or lead (Pb), and
combinations thereof in any of elemental, compound, or ionic form.
[0043] "Group V metal" refers to vanadium (V), niobium (Nb), tantalum (Ta),
and combinations
thereof in their elemental, compound, or ionic form.
[0044] "Group VIB" or "Group VIB metal" refers to chromium (Cr), molybdenum
(Mo), tungsten
(W), and combinations thereof in any of elemental, compound, or ionic form.
[0045] "Group VIII" or "Group VIII metal" refers to iron (Fe), cobalt (Co),
nickel (Ni), ruthenium
(Ru), rhenium (Rh), rhodium (Ro), palladium (Pd), osmium (Os), iridium (Ir),
platinum (Pt), and
combinations thereof in any of elemental, compound, or ionic form.
[0046] The term "support", particularly as used in the term "catalyst
support", refers to
conventional materials that are typically a solid with a high surface area, to
which catalyst materials
are affixed. Support materials may be inert or participate in the catalytic
reactions, and may be
porous or non-porous. Typical catalyst supports include various kinds of
carbon, alumina, silica, and
silica-alumina, e.g., amorphous silica alunninates, zeolites, alumina-boria,
silica-alumina-magnesia,
silica-alumina-titania and materials obtained by adding other zeolites and
other complex oxides
thereto.
[0047] "Molecular sieve" refers to a material having uniform pores of
molecular dimensions
within a framework structure, such that only certain molecules, depending on
the type of molecular
sieve, have access to the pore structure of the molecular sieve, while other
molecules are excluded,
e.g., due to molecular size and/or reactivity. Zeolites, crystalline
alunninophosphates and crystalline
silicoalunninophosphates are representative examples of molecular sieves.
[0048] W220 and W600 refer to waxy medium and heavy Group II base oil
product grades, with
W220: referring to a waxy medium base oil product having a nominal viscosity
of about 6 cSt at
100 C, and W600: referring to a waxy heavy base oil product having a nominal
viscosity of about 12
cSt at 100 C. Following dewaxing, typical test data for Group II base oils are
as follows:
Property Standard Test 220N 600N
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API Base Stock Category (API 1509 E.1.3) Group ll Group ll
API Gravity ASTM D1298 32.1 31.0
Specific Gravity at 60/60 F ASTM D1298 0.865 0.871
Density, lb/gal ASTM D1298 7.202 7.251
Viscosity, Kinematic ASTM D445
cSt at 40 C 41.0 106
cSt at 100 C 6.3 12.0
Viscosity, Saybolt ASTM D2161 212 530
SUS at 100 F
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 L0.5 L0.5
Sulfur, ppm Chevron <6 <6
Water, ppm ASTM D1744 <50 <50
Saturates, HPLC, wt % Chevron >99 >99
Aromatics, HPLC, wt % Chevron <1 <1
[0049] In this disclosure, while compositions and methods or processes are
often described in
terms of "comprising" various components or steps, the compositions and
methods may also
"consist essentially of" or "consist of" the various components or steps,
unless stated otherwise.
[0050] The terms "a," "an," and "the" are intended to include plural
alternatives, e.g., at least
one. For instance, the disclosure of "a transition metal" or "an alkali metal"
is meant to encompass
one, or mixtures or combinations of more than one, transition metal or alkali
metal, unless
otherwise specified.
[0051] All numerical values within the detailed description and the claims
herein are modified
by "about" or "approximately" the indicated value, and take into account
experimental error and
variations that would be expected by a person having ordinary skill in the
art.
[0052] In one aspect, the present invention is a process for making a base
oil product,
comprising
combining an atmospheric resid feedstock and a base oil feedstock to form a
base
oil feedstream;
contacting the base oil feedstream with a hydrocracking catalyst under
hydrocracking conditions to form a hydrocracked product;
separating the hydrocracked product into a gaseous fraction and a liquid
fraction;
contacting the liquid fraction with a dewaxing catalyst under
hydroisomerization
conditions, to produce a dewaxed product; and
optionally, contacting the dewaxed product with a hydrofinishing catalyst
under
hydrofinishing conditions to produce a hydrofinished dewaxed product.
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[0053] The base oil feedstock generally meets one or more of the following
property
conditions:
API gravity in the range of 15-40 or 15-30 or 15-25, or at least 15, or at
least 17,
optionally, less than the atmospheric resid feedstock;
VI in the range of 30-90 or 40-90 or 50-90 or 50-80, optionally, less than the
VI of the
atmospheric resid feedstock;
viscosity at 100 C in the range of 3-30 cSt or 3-25 cSt or 3-20 cSt, or at
least 3 cSt, or at
least 4 cSt;
viscosity at 70 C in the range of 5-25 cSt or 5-20 cSt or 5-15 cSt, or at
least 5 cSt, or at
least 6 cSt;
hot C7 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 5-40 wt.% or 5-30 wt.% or 10-25 wt.%, or at least
5 wt.% or
at least 10 wt.%, or at least 15 wt.%, or, optionally, greater than the wax
content of the base oil
feedstock;
nitrogen content of less than 2500 ppm or less than 2000 ppm or less than 1500
ppm
or less than 1000 ppm or less than 500 ppm or less than 200 ppm or less than
100 ppm;
sulfur content of less than 8000 ppm or less than 6000 ppm or less than 4000
ppm or
less than 2000 ppm or less than 1000 ppm or less than 500 ppm or less than 200
ppm, or in the
range of 100-8000 ppm or 100-6000 ppm or 100-4000 ppm or 100-2000 ppm or 100-
1000 ppm or
100-500 ppm or 100-200 ppm; and/or
1050+ F content in the range of 5-50 wt.% or 5-40 wt.% or 8-40 wt.%, or,
optionally,
greater than the 1050+ F content of the base oil feedstock.
[0054] Suitable base oil feedstocks may be from any crude oil feedstock, or
a fraction thereof,
including hydroprocessed intermediate streams or other feeds. Generally, the
base oil feedstock
contains materials boiling within the base oil range. Feedstocks may include
atmospheric and
vacuum residuum from a variety of sources, whole crudes, and paraffin-based
crudes.
[0055] The atmospheric resid (AR) feedstock generally meets one or more of
the following
property conditions:
API gravity in the range of 20-60 or 20-45 or 25-45, or at least 20, or at
least 22, or,
optionally, greater than the API of the base oil feedstock;
VI in the range of 50-200 or 70-190 or 90-180, or at least 80, or, optionally,
greater
than the VI of the base oil feedstock;
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viscosity at 100 C in the range of 3-30 cSt or 3-25 cSt or 3-20 cSt, or at
least 3 cSt, or at
least 4 cSt;
viscosity at 70 C in the range of 5-25 cSt or 5-20 cSt or 5-15 cSt, or at
least 5cSt, or at
least 6 cSt;
hot C7 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 5-40 wt.% or 5-30 wt.% or 10-25 wt.%, or at least
5 wt.% or
at least 10 wt.%, or at least 15 wt.%, or, optionally, greater than the wax
content of the base oil
feedstock;
nitrogen content of less than 2500 ppm or less than 2000 ppm or less than 1500
ppm
or less than 1000 ppm or less than 500 ppm or less than 200 ppm or less than
100 ppm;
sulfur content of less than 8000 ppm or less than 6000 ppm or less than 4000
ppm or
less than 2000 ppm or less than 1000 ppm or less than 500 ppm or less than 200
ppm, or in the
range of 100-8000 ppm or 100-6000 ppm or 100-4000 ppm or 100-2000 ppm or 100-
1000 ppm or
100-500 ppm or 100-200 ppm; and/or
1050+ F content in the range of 5-50 wt.% or 5-40 wt.% or 8-40 wt.%, or,
optionally,
greater than the 1050+ F content of the base oil feedstock.
[0056] In some aspects, AR feedstocks having property characteristics
described herein may be
advantageously derived from a light tight oil (LTO, e.g., shale oil typically
having an API of >45).
Suitable feedstocks may be Permian Basin feedstocks and elsewhere, including
Eagle Ford, Avalon,
Magellan, Buckeye, and the like.
[0057] Both the base oil feedstock and the atmospheric resid feedstock may
have any of the
foregoing properties within any of the noted broad and narrower ranges and
combinations of such
ranges.
[0058] The base oil feedstream generally comprises 10--60 wt.% atmospheric
resid
feedstock and 40-90 wt.% base oil feedstock, or 10-40 wt.% atmospheric resid
feedstock and
60-90 wt.% base oil feedstock, or 10-30 wt.% atmospheric resid feedstock and
70-90 wt.% base
oil feedstock, or 30-60 wt.% atmospheric resid feedstock and 40-70 wt.% base
oil feedstock, or
40-60 wt.% atmospheric resid feedstock and 40--60 wt.% base oil feedstock.
[0059] In certain embodiments, the base oil feedstream does not contain an
added whole
crude oil feedstock, and/or does not contain a vacuum residue feedstock,
and/or does not
contain a deasphalted oil feedstock component, and/or contains only
atmospheric resid
feedstock and base oil feedstock.
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[0060] While not limited to a straight run process, the process need not
include recycle of a
liquid feedstock as part of the base oil feedstream or as either or both of
the atmospheric resid
feedstock and the base oil feedstock. In certain embodiments, recycle of one
or more
intermediate streams may be desired, however.
[0061] The base oil feedstock may comprise vacuum gas oil, or consist
essentially of
vacuum gas oil, or consist of vacuum gas oil. The vacuum gas oil may be a
heavy vacuum gas oil
obtained from vacuum gas oil that is cut into a light fraction and a heavy
fraction, with the
heavy fraction having a cut point temperature range of about 950-1050 F.
[0062] The dewaxed product and/or the hydrofinished dewaxed product is
typically
obtained as a light base oil product and a heavy base oil product. The light
base oil product
generally has a nominal viscosity in the range of 4-8 cSt or 5-7 cSt at 100 C
and/or with the heavy
base oil product generally having a nominal viscosity in the range of 10-14
cSt or 11-13 cSt at 100 C.
The dewaxed product may be further separated into at least a light product
having a nominal
viscosity of about 6 cSt at 100 C, and/or at least a heavy product having a
nominal viscosity of about
12 cSt at 100 C, or a combination thereof.
[0063] One of the advantages associated with the process is that the yield
of the heavy
base oil product relative to the light base oil product may be increased by at
least about 2
Lvol.%, or at least about 5 Lvol.% (liquid volume %) compared with the same
process that does
not include the atmospheric resid feedstock in the lubricating oil feedstream.
In some
embodiments, the yield of the heavy base product may be increased by at least
about
Lvol.%, or at least about 20 Lvol.%, or at least about 30 Lvol.%, or at least
about 40 Lvol.%,
compared with the same process that does not include the atmospheric resid
feedstock in the
base oil feedstream.
[0064] In another aspect, the invention concerns a method for modifying a
conventional or
existing base oil process. In particular, a base oil process that comprises
subjecting a base oil
feedstream to hydrocracking and dewaxing steps to form a dewaxed product
comprising a
lighter product and a heavier product may be modified according to the
invention by combining
an atmospheric resid feedstock with a base oil feedstock to form the base oil
feedstream and
subjecting the base oil feedstream comprising the atmospheric resid feedstock
to the
hydrocracking and dewaxing steps of the base oil process to produce a dewaxed
product. The
dewaxed product may be optionally further contacted with a hydrofinishing
catalyst under
hydrofinishing conditions to produce a hydrofinished dewaxed product.
[0065] The invention further relates to a process for making a base oil,
comprising
contacting a base oil feedstock having a viscosity index of about 100 or
greater with a
11
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hydrocracking catalyst under hydrocracking conditions to form a hydrocracked
product,
wherein the base oil feedstock comprises vacuum gas oil having a front end cut
point of about
700 F or greater and a back end cut point of about 900 F or less; separating
the hydrocracked
product into a gaseous fraction and a liquid fraction; contacting the liquid
fraction with a
dewaxing catalyst under hydroisomerization conditions, to produce a dewaxed
product; and
optionally, contacting the dewaxed product with a hydrofinishing catalyst
under hydrofinishing
conditions to produce a hydrofinished dewaxed product; wherein, the dewaxed
product and/or the
hydrofinished dewaxed product has a viscosity index of 120 or greater after
dewaxing. The dewaxed
product and/or the hydrofinished dewaxed product may have a viscosity index of
130 or greater
after dewaxing, or 135 or greater after dewaxing, or 140 or greater after
dewaxing. The
hydrocracked product may have a viscosity index of at least about 135, or 140,
or 145, or 150. The
dewaxed products prepared by the process may be a Group III or Group III+
product.
[0066] By comparison to the use of a conventional VG0 feedstock, the use of
a vacuum gas oil
having a front end cut point of about 700 F or greater and a back end cut
point of about 900 F
or less, herein referred to as a medium vacuum gas oil (MVGO) provides an
improved waxy
product yield at a Group III or Group III+ viscosity of 4cSt 100 C of the MVGO
that is at least about 3
lvol.% greater than the same process that does not include the MVGO as the
base oil feedstock.
[0067] The invention further relates to a process that combines the two
process aspects,
i.e., in which a feedstock is used to derive the narrow cut-point fraction and
the same or a
different feedstock is used for the atmospheric resid fraction. The combined
process for making
a base oil from a base oil feedstock, or a fraction thereof, comprises
providing an atmospheric
resid fraction from a base oil feedstock, or a fraction thereof; separating
the base oil feedstock, or a
fraction thereof, and/or the base oil atmospheric resid fraction into a narrow
vacuum gas oil cut-
point fraction having a front end cut point of about 700 F or greater and a
back end cut point of
about 900 F or less to form an MVGO fraction and a residual HHVGO fraction;
using the HHVGO
fraction as the atmospheric resid feedstock in the first process to prepare a
dewaxed product and/or
hydrofinished dewaxed product; and/or using the MVGO fraction as the base oil
feedstock in a
second process to prepare a dewaxed product and/or hydrofinished dewaxed
product having a
viscosity index of 120 or greater after dewaxing. In certain embodiments, the
base oil feedstock may
comprise tight oil, particularly a light tight oil, or a fraction thereof. The
narrow vacuum gas oil cut-
point fraction may also be derived from the atmospheric resid fraction,
including an atmospheric
resid fraction derived from light tight oil.
[0068] Advantageously, the fractionation of the AR feedstock into MVGO and
HHVGO fractions
provides the ability to produce Group III/III+ base oil product while still
allowing the HHVGO fraction
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to be used with a conventional VG0 base oil feedstock to produce a Group II
base oil product. In
some embodiments, the use of MVGO to produce Group III/III+ base oil product
results in greater
yields of such products.
[0069] An illustration of a method or process according to an embodiment of
the invention is
shown schematically in FIG. 2a, in which conventional base oil hydrotreating,
hydrocracking,
hydrodewaxing, and hydrofinishing process steps, conditions, and catalysts are
used. By comparison
to a prior art base oil process schematic illustrated in FIG 1, FIG. 2a shows
the use of a feed blend of
VG0 and atmospheric resid (AR) where the conventional process typically uses
VG0 base oil
feedstock. FIG 2b further illustrates the use of an AR feedstock to form a
medium vacuum gas oil
fraction (MVGO) and a heavy VG0 fraction (HHVGO), with the MVGO fraction
feedstreann being used
to produce a Group III/III+ base oil product and the HHVGO fraction
feedstreann being combined
with a conventional VG0 base oil feedstock to produce a Group II base oil
product.
[0070] Catalysts suitable for use as the hydrocracking, dewaxing, and
hydrofinishing catalysts in
the process and method and associated process conditions are described in a
number of
publications, including, e.g., US Patent Publication Nos. 3,852,207;
3,929,616; 6,156,695; 6,162,350;
6,274,530;6,299,760; 6,566,296; 6,620,313; 6,635,599; 6,652,738;6,758,963;
6,783,663; 6,860,987;
7,179,366; 7,229,548;7,232,515; 7,288,182; 7,544,285, 7,615,196;
7,803,735;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;
WO 2017/044210; and others.
[0071] Catalysts suitable for hydrocracking, e.g., comprise materials
having hydrogenation-
dehydrogenation activity, together with an active cracking component support.
Such catalysts are
well described in many patent and literature references. Exemplary cracking
component supports
include silica-alumina, silica- oxide zirconia composites, acid-treated clays,
crystalline
aluminosilicate zeolitic molecular sieves such as zeolite A, faujasite,
zeolite X, and zeolite Y, and
combinations thereof. Hydrogenation-dehydrogenation components of the catalyst
preferably
comprise a metal selected from Group VIII metals and compounds thereof and
Group VIB metals and
compounds thereof. Preferred Group VIII components include cobalt and nickel,
particularly the
oxides and sulfides thereof. Preferred Group VIB components are the oxides and
sulfides of
molybdenum and tungsten. Examples of a hydrocracking catalyst which would be
suitable for use in
the hydrocracking process step are the combinations of nickel-tungsten-silica-
alumina, nickel-
molybdenum-silica-alumina and cobalt-molybdenum-silica-alumina. Such catalysts
may vary in their
activities for hydrogenation and for cracking and in their ability to sustain
high activity during long
periods of use depending on their compositions and preparation.
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[0072] Typical hydrocracking reaction conditions include, for example, a
temperature of from
450 F to 900 F (232 C to 482 C), e.g., from 650 F to 850 F (343 C to 454 C); a
pressure of from 500
psig to 5000 psig (3.5 MPa to 34.5 MPa gauge), e.g., from 1500 psig to 3500
psig (10.4 MPa to 24.2
MPa gauge); a liquid reactant feed rate, in terms of liquid hourly space
velocity (LHSV) of from 0.1 hr
-
1 to 15 hr-1 (v/v), e.g., from 0.25 hr-1 to 2.5 hr-1; a hydrogen feed rate, in
terms of H2/hydrocarbon
ratio, of from 500 SCF/bbl to 5000 SCF/bbl (89 to 890 ne H2/m3 feedstock) of
liquid base oil
(lubricating) feedstock, and/or a hydrogen partial pressure of greater than
200 psig, such as from
500 to 3000 psig; and hydrogen re-circulation rates of greater than 500 SCF/B,
such as between 1000
and 7000 SCF/B.
[0073] Hydrodewaxing is used primarily for reducing the pour point and/or
for reducing the
cloud point of the base oil by removing wax from the base oil. Typically,
dewaxing uses a catalytic
process for processing the wax, with the dewaxer feed is generally upgraded
prior to dewaxing to
increase the viscosity index, to decrease the aromatic and heteroatonn
content, and to reduce the
amount of low boiling components in the dewaxer feed. Some dewaxing catalysts
accomplish the
wax conversion reactions by cracking the waxy molecules to lower molecular
weight molecules.
Other dewaxing processes may convert the wax contained in the hydrocarbon feed
to the process by
wax isonnerization, to produce isonnerized molecules that have a lower pour
point than the non-
isonnerized molecular counterparts. As used herein, isonnerization encompasses
a
hydroisonnerization process, for using hydrogen in the isonnerization of the
wax molecules under
catalytic hydroisonnerization conditions.
[0074] Dewaxing generally includes processing the dewaxer feedstock by
hydroisonnerization to
convert at least the n-paraffins and to form an isonnerized product comprising
isoparaffins. Suitable
isonnerization catalysts for use in the dewaxing step can include, but are not
limited to, Pt and/or Pd
on a support. Suitable supports include, but are not limited to, zeolites CIT-
1, IM-5, SSZ-20,SSZ-
23,SSZ-24, SSZ-25,SSZ-26, SSZ-31, SSZ-32, SSZ-32,SSZ-33,SSZ-35, SSZ-36,SSZ-37,
SSZ-41, SSZ -42, SSZ-
43, SSZ-44, SSZ-46, SSZ-47, SSZ-48, SSZ-51, SSZ-56, SSZ-57, SSZ-58, SSZ-59,
SSZ-60, SSZ-61, SSZ-63,
SSZ-64, SSZ-65, SSZ-67, SSZ-68, SSZ-69, SSZ-70, SSZ-71, SSZ-74, SSZ-75, SSZ-
76, SSZ-78, SSZ-81, SSZ-
82, SSZ-83, SSZ-86, SUZ-4, TNU-9, ZSM-S, ZSM-12, ZSM-22, ZSM-23, ZSM-35, ZSM-
48, EMT-type
zeolites, FAU-type zeolites, FER-type zeolites, MEL-type zeolites, MFI-type
zeolites, MIT-type
zeolites, MTW-type zeolites, MWW-type zeolites, MRE-type zeolites, TON-type
zeolites, other
molecular sieves materials based upon crystalline alunninophosphates such as
SM-3, SM-7, SAP0-11,
SAPO-31, SAPO-41, MAPO-Il and MAPO-31. Isonnerization may involve also a Pt
and/or Pd catalyst
supported on an acidic support material such as beta or zeolite Y molecular
sieves, silica, alumina,
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silica-alumina, and combinations thereof. Suitable isonnerization catalysts
are well described in the
patent literature, see, e.g., US. Pat. Nos. 4,859,312; 5,158,665; and
5,300,210.
[0075] Hydrodewaxing conditions generally depend on the feed used, the
catalyst used,
whether or not the catalyst is sulfided, the desired yield, and the desired
properties of the base oil.
Typical conditions include a temperature of from 500 F to 775 F (260 C to 413
C); a pressure of from
15 psig to 3000 psig (0.10 MPa to 20.68 MPa gauge); a LHSV of from 0.25 hi-I-
to 20 hr-1; and a
hydrogen to feed ratio of from 2000 SCF/bbl to 30,000 SCF/bbl (356 to 5340 nn3
H2/m3 feed).
Generally, hydrogen will be separated from the product and recycled to the
isonnerization zone.
Suitable dewaxing conditions and processes are described in, e.g., U.S. Pat.
Nos. 5,135,638;
5,282,958; and 7,282,134.
[0076] Waxy products W220 and W600 may be dewaxed to form 220N and 600N
products that
may be suitable (or better suited) for use as a lubricating base oil or in a
lubricant formulation. For
example, the dewaxed product may be mixed or admixed with existing lubricating
base oils in order
to create new base oils or to modify the properties of existing base oils,
e.g., to meet particular
target conditions, such as visconnetric or Noack target conditions, for
particular base oil grades like
220N and 600N. Isonnerization and blending can be used to modulate and
maintain pour point and
cloud point of the base oil at suitable values. Normal paraffins may also be
blended with other base
oil components prior to undergoing catalytic isonnerization, including
blending normal paraffins with
the isonnerized product. Lubricating base oils that may be produced in the
dewaxing step may be
treated in a separation step to remove light product. The lubricating base oil
may be further treated
by distillation, using atmospheric distillation and optionally vacuum
distillation to produce a
lubricating base oil.
[0077] Typical hydrotreating conditions vary over a wide range. In general,
the overall LHSV is
about 0.25 hi-I-to 10 hr-1 (v/v), or alternatively about 0.5 hi-I-to 1.5 hr-1.
The total pressure is from
200 psig to 3000 psig, or alternatively ranging from about 500 psia to about
2500 psia. Hydrogen
feed rate, in terms of H2/hydrocarbon ratio, are typically from 500 SCF/Bbl to
5000SCF/bbl (89 to
890 nn3 H2/m3 feedstock), and are often between 1000 and 3500 SCF/Bbl.
Reaction temperatures in
the reactor will typically be in the range from about 300 F to about 750 F
(about 150 C to about
400 C), or alternatively in the range from 450 F to 725 F (230 C to 385 C).
[0078] In practice, layered catalyst systems may be used comprising
hydrotreating (HDT, HDM,
DEMET, etc.), hydrocracking (HCR), hydrodewaxing (HDW), and hydrofinishing
(HFN) catalysts to
produce intermediate and/or finished base oils using single or nnultireactor
systems. A typical
configuration includes two reactors with the first reactor comprising layered
catalysts providing
DEMET, HDT pretreatment, NCR, and/or HDW activity. Differing catalysts
performing similar
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functions, e.g., different levels of hydrocracking activity, may be used as
well, e.g., in different layers
within a single reactor or in separate reactors.
EXAMPLES
[0079] Samples of vacuum gas oil (VGO) and atmospheric resid (AR) were
obtained from
commercially available sources and used in the process schemes illustrated in
FIG's. 3a, 3b, 4, and 5.
FIG's 3a and 3b show larger process research unit configurations that were
generally used to
evaluate larger quantities of feedstocks when available. FIG's 4 and 5 show
smaller bench scale
units used to evaluate smaller feedstocks quantities and were primarily used
to evaluate all AR
samples.
[0080] Research unit process conditions used included 0.5 LHSV-1, reactor
H2 partial pressure of
1750 psia, hydrogen feed gas oil (recycle) ratio of 4500 scfb, and reactor
temperatures in range of
700-770+ F, with the downstream reactor R2 temperature being maintained at 20
F hotter than the
upstream R1 reactor. An ascending temperature profile was imposed, 120 F and
40 F AT for R1 and
R2, respectively. Waxy product target viscosity indexes (VI's) were set at 109
at 6.0 cSt at 100 C
(W220) and 11.8 cSt at 100 C (W600).
[0081] Bench scale process conditions used included 0.5 LHSV-1, reactor
pressure of 1850 psig,
hydrogen feed gas oil ratio of 4500 scfb, and reactor temperatures in range of
700-770+ F, with the
downstream reactor R2 temperature being maintained at 20 F hotter than the
upstream R1 reactor.
Waxy product target viscosity indexes (VI's) were set at 109 at 6.1 cSt at 100
C (220R) and 11.8 cSt at
100 C (600R).
[0082] The catalyst loading in each of reactors R1 and R2 (according to
each of FIG's 3a, 3b, 4,
and 5) was a conventional scheme for base oil production comprising layered
hydronnetallation,
hydrotreating, and hydrocracking catalysts. Typical configurations included
layered catalyst systems
comprising one or more DEMET layers, high activity HCR/HDT, HCR, and low
activity HCR catalysts
for both R1 and R2.
[0083] FIG's 3a, 3b, 4, and 5 each show feedstreanns 10 and H2 inlet 11 to
each of reactors R1
and R2, and other intermediate flow streams 20, 30, H2 recycle stream 31,
whole liquid product
(WLP) stream 32 that are sent to separators and/or condensers (Cl to C4, 51,
and V3) to provide the
respective product streams C2B, C3B, C40, C4B, STO, STB, V30, and V3B shown in
each figure and as
noted in the following examples.
Example 1 - Vacuum Gas Oil (VGO) Feedstock (comparative feedstock)
[0084] A sample of vacuum gas oil (VGO) feedstock from a commercially
available source used
to produce base oil products was obtained and analyzed as a comparative base
case. The VGO
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feedstock was used in the following examples according to the process
configurations shown in
FIG's. 3a, 3b, 4, and 5. The properties of this VG0 feedstock (sample ID 2358)
are shown in Table 1.
Table 1 - Properties of Vacuum Gas Oil (VGO) Feedstock
Feed VG0
Property Property Value
API Gravity 18
Viscosity Index, VI (D2270) 52
Viscosity, 100 C (cSt) 13.23
Viscosity, 70 C (cSt) 37.56
Hot C7 Asphaltenes (wt.%)
wax content (wt.%) 7
N content (ppm) 1620
S content (ppm) 31420
1050+ (wt.%) 4.7
Simdist ( F)
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 Resid (AR) Feedstocks
[0085] Samples of atmospheric resids (AR1 to AR5) from commercially
available sources were
obtained and analyzed. The properties of these AR samples, which were used as
feedstock
components according to the invention, are shown in Table 2.
Table 2 - Properties of Atmospheric Resid (AR) Feedstocks
Feed AR Sample Property Value
Property AR1 AR2 AR3 AR4 AR5
Sample ID 2147 2188 2361 2591 2614
API Gravity 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
Hot C7 Asphaltenes (wt.%) 0.12 0.0234 0.0379
wax content (wt.%) 24 14 25 21
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N content (ppm) 808 70.7 623 340 271
S content (ppm) 5654 805 3938 2266 558
1050+ F (wt.%) 24.2 8.3 15.6 11.9 14.3
Simdist ( F)
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
Example 3 - Properties of Blends of Atmospheric Resid (AR) Feedstocks with
Vacuum Gas Oil (VGO)
Feedstock
[0086] Samples of
the atmospheric resids AR1 to AR5 of example 2 were blended with the
vacuum gas oil (VGO) feedstock of example 1 on a weight ratio basis and the
blends analyzed. The
properties of these AR/VGO blend samples, which were used as illustrative
feedstocks according to
the invention, are shown in Table 3.
Table 3 - Properties of Atmospheric Resid (AR) and Vacuum Gas Oil (VGO)
Feedstock Blends
F AR/VGO Blend (wt/wt) Sample Property Value
eed
45% AR1/ 50% AR2/ 53% AR3/ 20% AR4/ 20% AR5/
Property
55% VGO 50% VGO 47% VGO 80% VGO 80%
VGO
Sample ID 2148 2190 2394 3294 4122
API Gravity 20.9 25.9 19.9 19.9 20.6
Viscosity Index, VI (D2270) 73 100 63 72 69
Viscosity, 100 C (cSt) 13.68 6.912 11.99 11.63 11.12
Viscosity, 70 C (cSt) 37.28 15.21 32.4 30.59 29.12
Hot C7 Asphaltenes (wt.%) 0.0386
wax content (wt.%) 18 8
N content (ppm) 1540 1050 1460 1230 1270
S content (ppm) 20490 15630 26160 26620 25880
1050+ (wt.%) 6.4 6 6.8 7.3
Simdist ( F)
IBP 346 551 500 431
5% 702 551 692 693 676
15% 674 760 765 761
20% 804 716 781 786 784
30% 840 778 815 820 818
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35% 802 830 835 833
40% 871 823 844 850 848
45% 841 857 865 864
50% 899 860 871 880 879
55% 877 884 895 894
60% 930 894 898 910 910
65% 912 913 927 926
70% 960 929 927 942 942
75% 947 942 960 960
80% 999 969 958 979 980
85% 992 975 1000 1002
90% 1058 1021 993 1027 1030
95% 1132 1064 1015 1066 1075
99% 1172 1046 1166 1246
EP 1327 1216 1051 1204 1313
Example 4- Evaluation of Group II Base Oil Production from Blends of
Atmospheric Resid (AR)
Feedstock with Vacuum Gas Oil (VGO) Feedstock
[0087] The blend feedstock samples AR1 to AR5 of the atmospheric resids
with vacuum gas oil
(VGO) of example 3 were evaluated for Group II base oil production according
to the process
represented by FIG. 3b. Group II results were also obtained using the VGO
feedstock of example 1
(according to the process of FIG. 3a) for comparison.
[0088] Bench scale process conditions used included 0.5 LHSV-1, reactor
pressure of 1850 psig,
hydrogen feed gas oil ratio of 4500 scfb, and reactor temperatures in range of
700-770+ F, with the
downstream reactor R2 temperature being maintained at 20 F hotter than the
upstream R1 reactor.
Waxy product target viscosity indexes (VI's) were set at 109 at 6.1 cSt at 100
C (220R) and 11.8 cSt at
100 C (600R).
[0089] Base oil production results compared with VGO feedstock alone for
the AR1/VGO blend
are shown in Table 4a, results for blends of AR2 and AR3 with VGO are shown in
Table 4b, and
results for blends of AR4 and AR5 with VGO are shown in Table 4c, with each
set of results
determined using the AR/VGO blends of example 3.
[0090] As shown in
Table 4a, using the AR1/VGO blend as lube oil process feed showed an
improvement in heavy base oil product W600 yield of 57.5 vol% vs. 19.3 vol%
when the feed does
not include the atmospheric resid AR1 component. This improvement in heavy
base oil yield is
significant even though the AR1/VGO blend did show some loss in hydrocracking
(-15 F) and HDN
activity loss (19 F or above). The advantage of high W600 yield suggests a
more active and robust
HDN catalyst system would also be beneficial, particularly for high nitrogen-
containing feedstocks.
Table 4a ¨ Base Oil Production for AR1/VGO (wt/wt) blend
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Feed VG0 45% AR1/55% VG0
Sample ID 2018 2148 2148 2148
Apparent Conversion <700 F,
30.0 22.5 22.0 36.0
(Ivol.%)
R ID 90-326 866- 90-326 1250- 90-326 1514- 90-
326 2042-
un
890 1274 1538 2066
R1 Temperature ( F) 720 720 728 754
R2 Temperature ( F) 740 740 748 774
H2 Average Pressure (psia) 1855 1808 1812 1872
Recycle Gas (SCF/B) 4444 4488 4467 4493
No Loss Product Yields (wt.%):
Cl 0.06 0.12 0.11 0.19
C2 0.1 0.12 0.12 0.22
C3 0.2 0.19 0.2 0.37
i-C4 0.09 0.05 0.05 0.16
n-C4 0.21 0.14 0.14 0.37
C5-180 F 1.1 0.99 0.95 1.5
180-250 F 1.9 0.98 0.98 2.4
250-550 F 15.2 10.1 9.9 18.0
550-650 F 9.3 7.6 7.5 10.1
650-700 F 6.0 5.5 5.4 6.2
700-750 F 7.0 7.2 6.8 7.0
750-800 F 9.3 9.5 9.2 8.8
800-900 F 23.4 22.8 22.7 18.8
900-EP F 25.2 33.6 34.9 25.0
TOTAL C4- 0.66 0.62 0.61 1.31
TOTAL C5+ 98.3 98.3 98.3 97.9
H2 Consumption (CHEM)(SCF/B) 1229 794 804 961
Mass Closure (wt.%) 99.5 100.5 100.1 99.9
Actual yield:
Waxy W220 Yield (vol.%) 49.1 19.0 19.6 25.6
Waxy W600 Yield (vol.%) 19.3 57.5 57.5 36.7
Total Lube Yield (vol.%) 68.4 76.5 77.1 62.3
C40:
API 30 30.7 30.4 32.7
Density (g/m1) 0.8406 0.8372 0.8383 0.8264
Temperature ( C) 70 70 70 70
N content (ppm) 2.1 5.3 7.9 1.82
S content (ppm) <5 <5 <5
Viscosity, 70 C (cSt) 14.27 10.33 10.34 9.706
Viscosity, 100 C (cSt) 6.620 5.066 5.067 4.918
Viscosity Index, VI (D2270) 105 102 102 117
C4B:
API 30.5 30 29.9 31.8
Density (g/m1) 0.8381 0.8406 0.8415 0.8313
Temperature ( C) 70 70 70 70
N content (ppm) 1.3 4.6 6.6 1.45
S content (ppm) 5.6 7.73 <5
Viscosity, 70 C (cSt) 28.48 28.94 29.42 26.68
Viscosity, 100 C (cSt) 12.02 12.18 12.31 11.68
Viscosity Index, VI (D2270) 114 113 112 127
Ascending profile, F/ F in R1/R2 120/40 120/40 70/30
70/30
C2 B:
API 35.9 36.3 36.2 39
Density (g/m1) 0.8447 0.8423 0.843 0.8289
Temperature ( C) 15.56 15.56 15.56 15.57
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Feed VG0 45% AR1/55% VG0
Sample ID 2018 2148 2148 2148
C2B Simdist (wt.%) F
0.5% 96 94 97 95
5% 217 219 221 209
10% 270 296 299 259
15% 320 360 362 310
20% 367 404 406 358
25% 403 441 443 392
30% 434 475 477 421
35% 464 505 506 452
40% 492 529 531 480
50% 540 573 573 529
55% 562 591 591 550
60% 580 607 607 573
65% 600 625 624 592
70% 618 639 639 611
75% 635 653 652 630
80% 652 666 665 649
85% 667 678 677 666
90% 682 691 689 682
95% 698 704 702 698
99% 719 722 720 719
99.5% 725 729 728 726
C40 Simdist (wt.%) F
1% 692 685 685 690
5% 725 712 711 717
10% 742 724 722 729
15% 757 733 732 739
20% 771 741 739 748
25% 784 749 748 757
30% 795 756 756 765
35% 807 764 763 774
40% 818 771 771 782
50% 840 786 786 799
55% 851 793 793 808
60% 862 801 801 817
65% 873 810 810 827
70% 884 818 818 837
75% 895 828 828 848
80% 908 839 839 859
85% 921 851 851 873
90% 937 865 865 888
95% 959 886 886 911
99% 994 922 921 948
100% 1004 935 934 963
C4B Simdist (wt.%) F
0.5% 740 710 708 718
5% 828 770 769 786
10% 865 801 800 820
15% 888 824 823 844
20% 906 843 842 863
25% 920 860 859 880
30% 932 875 874 894
35% 942 889 888 907
40% 952 902 902 920
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Feed VGO 45% AR1/55% VG0
Sample ID 2018 2148 2148 2148
50% 971 929 929 945
55% 979 942 943 958
60% 988 957 958 973
65% 996 973 975 988
70% 1005 991 993 1005
75% 1014 1011 1014 1025
80% 1024 1037 1041 1049
85% 1036 1068 1073 1079
90% 1050 1114 1122 1123
95% 1071 1184 1197 1192
99% 1111 1284 1308 1296
99.5% 1127 1305 1330 1318
[0091] Table 4b presents the results obtained for atmospheric resid samples
AR2 and AR3 that
are each blended with vacuum gas oil (VGO). As shown, the AR2/VG0 blend (90-
326-3242-3266)
provided significant improvements in both actual waxy W600 yield and total
actual waxy yield if the
same W220 VI (109 or close) is targeted, 36.6% vs. 18.6 for waxy 600R yield,
and 69.4% vs. 53.5% for
total waxy yield. While a higher waxy product nitrogen content was obtained,
the high product N
content could be reduced, as shown in 90-326-3098-3122, at the expense of waxy
W600R yield and
total waxy base oil yield (6% yield decrease for W600R and 2% yield decrease
for total waxy base oil
yield).
[0092] From Table 4b, the AR3/VG0 blend (88-342-3726-3750) showed
significant actual waxy
W600R yield improvement compared to VGO feed alone, 31.9% vs. 18.6%. The total
actual waxy
base oil yield remained the same, while the waxy products from the AR3/VG0
blend showed slightly
higher nitrogen content.
[0093] Table 4c presents the results obtained for atmospheric resid samples
AR4 and AR5 that
are each blended with vacuum gas oil (VGO). As shown, two separate runs were
performed at
different hydrocracking severities for each of the VGO comparative feed and
the AR4/VG0 and
AR5/VG0 blends.
Table 4b - Base Oil Production from AR2/VG0 and AR3/VG0 (wt/wt) blends
Feed VGO 53% AR3/47% VGO 50% AR2/50% VGO
Sample ID 2358 2394 2190
Conversion,
40.2 31.3 25.6 31.7 27.5
700 F- (lvol.%)
R ID 88-342 3342- 88-342 3726- 88-342 3846-
90-326 3098- 90-326 3242
un -
366 3750 3870 3122 3266
1
R1 Temperature
723 718 713 715 703
( F)
= - R1 Temperature
.
743 738 733 735 723
"
( F) i
Overall LHSV (hr-') ' 0.5 0.5 0.5 0.49 0.49
22
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Pressure (psig) 2000 , 2000 , 2000 2127 2127
!
H2 Avg Pressure .
1729 1771 1782 1914 1936
(psia) . ,
Recycle Gas .
4397 4522 , 4465 4576 4545
(SCF/B)
No Loss Product .
Wt.% Vol.% ! Wt.% Vol.% ! Wt.% Vol.% Wt.% Vol.% : Wt.% Vol.%
Yields:
C5-250 F 4.1 5.3 3.2 4.2 2.2 2.9 1.5 1.9 i
0.8 1.0
250-700 F 37.9 42.3 i 30.3 33.7 25.9 28.8 31.5
33.9 27.8 29.9
700-EP F 55.1 59.8 . 64.3 68.7 69.7 74.4 66.0
68.3 ! 70.5 72.5
Total C4- 1.6 ] 0.9 0.7 0.46 i 0.32
Total C5+ 97.0 107.4 ' 97.8 106.6 97.8 106.0
98.95 104.18 1 99.05 103.5
H2 Consumption
1311 982 857 714 689
(CHEMHSCF/B)
Mass Closure
98.6 98.9 99.8 99.75 i 99.39
(wt.%)
. .
Actual waxy .
product yield W22 W60 W22, W220 W600
o W600 W220 W600 : W220 W600
0 0
feed basis
Waxy product
34.9 18.6 21.6 31.9 23.4 37.1 36.8 30.6 ' 32.8 36.6
yield (vol.%)
Total Lube Yield -
53.5 53.5 60.5 67.4 69.4
(vol.%) 1
N (ppm) 0.8 0.5 1.8 1.4 3.2 2.9 2.47 1.91 .
7.85 7.48
S (ppm) <5 6.3 5.7 6.9 6.8 10.0 <5 7.25
10.1 15.6
Viscosity, 70 C
12.07 28.21 11.98 28.99 11.96 30.77 11.13 28.56 . 11.39 29.1
(cSt)
Viscosity, 100 C
5.802 12 5.767 12.13 5.715 12.67 5.461 12.14 5.515 12.14
(cSt)
Viscosity Index, VI
109 117 109 112 104 108 113 117 107 110
(D2270)
23
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Table 4c - Base Oil Production from AR4/VG0 and AR5/VG0 (wt/wt) Blends
i 20% i 20% 1 20% i 20%
Feed 1 VG() i VG() 1 AR4/80% AR4/80% -
AR5/80% l AR5/80%
,
VG0 i VG0 VG0 ! VG0
,
e-
Sample ID ; 2358 ; 2358 ; 3924 ; 3924 ; 4122
! 4122
Run ID 4560-
6 4968-5040 ; 5328-5424 ; 6554-6722 7010-7154
= =
R1 Temperature -
717 730 725 715 733 ; 718
( F)
R2 Temperature
737 = 750 : 745 735 753 738
( F)
LHSV R1/R2 1.0/0.97 , 1.03/1.0 ; 1.0/0.97 . 1.0/1.0
1.0/1.0 1 1.0/1.0
Total Pressure
1827 - 1845 1843 . 1820 1 1858 1851
(psig)
Gas Rate
4405 : 4407 4423 4463 4350 4404
No Loss Product
Yields (wt.%):
C5-180 F 1.5 = 2.1 = 1.7 E 1.3 2.0 i
1.3
180-250 F 1.0 ' 1.9 . 1.5 ' 0.7 1.8
0.7
250-550 F 13.7 ; 19.6 ; 16.3 ; 10.6 19.2 =
11.2
550-700 F 16.4 = 18.1 1 16.6 - 15.2 17.6
23.7
700+ F 64.0 54.5 i 60.8 69.5 56.7 60.5
C5+ 96.6 - 96.3 : 97.0 - 97.2 97.2 97.5
Mass Closure
100 99.4 . 98.9 - 99.2 99 99
(wt.%)
Average CAT
727 : 740 735 : 725 743 728
( F)
Waxy product W2 W6 W2 W6 W22 W60 W22 W60 W22 W60 W22 W60
yield: 20 00 20 00
0 0 0 0 0 0 0 0
Product Rate,
18. 18. 8.4 17.4 11.9 18.0 10.9
40 KBPD feed 4.7 16.1 939 17.6
92 6 5 3 2 3 5
basis (KBPD)
Viscosity, 100 C 6.3 11. ; 6.0 11. 6.00 11.8 : 6.11 11.7
6.00 ; 6.29
11.8
(cSt) 96 801 E 64 799 E 8 01 E 8 98 3 11.8 1
1
Viscosity Index, - 11
86 102 ! 4 122 116 119 = 107 109 118 122 : 105
107
VI (D2270)
Noack Volatility ; 14. E 11.
3 : 0.9 1 11.3 1.3 : 12.7 1.8 11.4
1.1 i 12.2 1.7
24
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[0094] Results from Table 4c provide a basis for comparison of waxy base
oil yields at a viscosity
index (VI) of 109 for W220 for AR2/VG0, AR4/VG0, and AR5/VG0 blends, as shown
in Table 4d. At
109 W220 VI, compared to VG0 feed alone, the 50% AR2/VG0 blend feed showed a
waxy base oil
yield improvement in W600 yield of 33.7% compared with a W600 yield of 25.8%
for VG0 feed alone
that does not include the atmospheric resid AR2 component. A total waxy base
oils yield of 68.7%
for the AR2/VG0 blend was obtained compared with a total waxy base oils yield
of 66.1% when the
feed did not contain the AR2 blend component.
[0095] The 20% AR4/VG0
blend also showed improvements in both W600 yield of the
AR4/VG0 blend compared with the VG0 feed by itself ( 28.4% vs. 25.8%), in W220
yield of the
AR4/VG0 blend compared with the VG0 feed by itself (42.9% vs. 40.3%), and the
total waxy base oil
yield of the AR4/VG0 blend compared with the VG0 feed by itself (71.3% vs.
66.1%).
[0096] Similarly, the 20% AR5/VG0 showed improvement in W220 yield of the
AR5/VG0 blend
compared with the VG0 feed by itself (44.4% vs.40.3%) and in total waxy base
oil W600 yield of the
AR5/VG0 blend compared with the VG0 feed by itself (68.1% vs. 66.1%).
Table 4d - Atmospheric Resid/Vacuum Gas Oil (AR/VGO) Blend Yield Comparison
20% AR4/80% 20% AR5/80%
Feed VG0 50% AR2/50% VG0 VG0 VG0
Sample ID 2358 2190 3924 4122
W220 VI 109 109 109 109
W220 yield (vol.%) 40.3 35.0 42.9 44.4
W600 yield (vol.%) 25.8 33.7 28.4 23.8
Total waxy yield (vol.% 66.1 68.7 71.3 68.1
Average CAT (T) 738 713 727 740
Example 5 - Evaluation of Atmospheric Resids (AR) to Provide Medium Grade
Vacuum Gas Oils
(MVGO) for Group III/III+ Base Oil Production
[0097] Samples of atmospheric resid (AR) were evaluated to provide medium
grade vacuum gas
oils (MVGO) for use in producing group III/III+ base oils. The MVGO samples
were derived from the
corresponding AR samples as distillation cuts in the following ranges: AR2 cut
range of 717-876 F;
AR4 cut range of 725-882 F; and, AR5 cut range of 716-882 F. Table 5a presents
properties of the AR
samples AR2, AR4, and AR5 and the corresponding MVGO derived cuts MVG02,
MVG04, and
MVG05. Properties for the comparative vacuum gas oil (VGO) are also included.
[0098] The three atmospheric resid (AR) derived MVGO's were evaluated using
the process
configuration of FIG. 4 for the production of group III base oils at different
dewaxing severities with
different waxy viscosity indexes (VI) at a kinematic viscosity (KV100) of
about 4 cSt at 100 C. Table 5b
summarizes the yields for the comparative case of VG0 by itself, and MVGO's
derived from AR2,
AR4, and AR5 feeds, designated as MVG02, MVG04, and MVG05 feeds, respectively.
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Table 5a - Properties of Atmospheric Resid (AR) and MVGO Feeds
Feed VG0 AR2
MVG02 AR4 MVG04 AR5 MVG05
Sample ID: 2326 2411 3106 2591 3816 2614 4108
API Gravity 25.3 36.1 35.6 32.6 34.2 32.6 33.4
Density (g/m1) 0.8672 0.809 0.8112 0.827 0.8184 0.8271
0.8229
Temperature ( C) 70 70 70 70 70 70 70
Viscosity Index, VI
72 151 128 134 124 123 117
(D2270)
Viscosity, 100 C (cSt) 4.208 4.575 4.339 6.425 4.635
6.511 5.138
Viscosity, 70 C (cSt) 8.436 8.455 8.167 13.04 8.914 .
13.5 10.25
Hot C7 Asphaltenes
0.0045 0.0046 0.0063 : 0.0379 0.0105
(wt.%)
Low Level N (ppm) 735 : 72.8 59.2 340 142 i
126
S (ppm) 21710 705 2266 443
CI (ppm) 41 7.2 58
H by NMR - 14.06 13.81
Dewaxed Oil (DWO .-
'
Viscosity Index, VI
53 111 106 1 108 100
(D2270)
Viscosity, 100 C (cSt) 4.484 ; 4.716 5.115 7.038
5.665
Visosity, 40 C (cSt) 27.49 : 24.54 28.68 46.84
34.91
Cloud point ( C) -13 i -11 -11 -12
Pour point ( C) -16 -14 -14 -14
Wax content (wt.%) 8.4 22.2 25.5 21.5 21.5 17.5
VI droop from SDW 19 , 17 18 15 17
SIMDIST TBP (wt.%), F
0.5% 527 337 696 484 694 330 683
5% 631 496 718 589 727 543 725
10% 668 565 732 636 740 625 742
20% 706 642 749 699 759 717 766
30% 730 698 764 746 775 774 784
40% 747 747 779 785 790 816 800
50% 762 794 794 824 804 856 814
60% 776 844 810 869 818 896 828
70% 1 790 903 827 920 834 942 843
80% 805 973 844 982 850 1003 858
90% 825 1067 864 1070 869 1096 878
95% 841 1143 878 1136 882 1173 894
99.5% 907 1330 908 1253 916 1339 942
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Table 5b - Comparison of Yields for VG0 and MVGO Feeds for Group Ill Base Oil
Production
-- Feed VG0 MVG02 I MVG04 I MVG05
Sample ID 2326 2326 3106 - 3106 3816 3816 .
3816 p 4108 4108
Run ID 601- 601- 601- 601- 601-
601-
601-65- 601-65- 601-65-
62- 62- 65- 65- 65- 65-
669- 1077- : 4893- 5109- 5469-
6093- 6549-
4029 4269
885 1221 ! 5037
5277 5613 6309 6717
R1
Temperature 720 740 680 660 - 720 710 695 705 720
F
R2 .
Temperature 740 760 700 680 . 740 730 715 725 740
F
LHSV (hr-1) 0.55 0.55 0.56 0.55 0.55 0.55 0.55
0.55 0.55
Total Pressure
1850 1850 1900 1900 1850 ' 1850 1850
1850 1850
(psig)
Gas Rate 3989 1 3985 4350.5 4400 1 4034 3990 3991 4395 1
4362
(SCFB)
No Loss Yields
(wt.%): .
Cl 0.2 0.3 0.0 0.0 0.1 1 0.1 ; 0.0 0.1
0.1
C2 0.2 0.4 0.1 0.0 0.1 I 0.1 . 0.1 0.1
0.1
C3 0.5 0.8 0.3 0.1 0.9 1 0.4 0.2 0.3 0.5
i-C4 0.3 0.6 0.8 0.3 . 1.1 i 0.8 0.4 0.6
1.0
n-C4 0.5 0.8 0.4 0.2 0.7 l 0.5 0.2 0.4 0.7
C5-180 F 2.4 3.9 3.6 1.6 5.2 3.3 2.1 3.1 6.0
180-250 F 2.7 4.9 3.2 1.2 4.4 , 3.2 1.5 3.1 5.2
250-550 F 24.6 34.8 24.1 12.0 29.3 . 22.7 14.5
22.2 35.1
550-700 F . 26.4 24.6 13.2 8.8 13.8 12.0 8.9 12.3 15.6
700 F+ 45.5 34.3 55.9 77.0 46.4 . 58.5 73.2
61.6 42.1
C5+ F 101.7 102.5 100.1 100.6 99.0 99.8 1 100.2
102.3 1 104.0
Mass Closure
99.5 99.2 99.7 99.8 99.7 99.9 99.2
99.5
(wt.%) . 99.8
STB Results: .
!
Viscosity Index,
123 133 144 136 142 140 136 135 138
VI (D2270)
Viscosity, 3.829 3.682 4.125 4.128 3.936 4.036 4.235
4.366 4.133
100 C (cSt)
Viscosity, 70 C
7.05 6.633 7.516 7.604 . 7.116 7.358 7.844 8.15
7.595
(cSt)
Actual STB
yield, on feed 41.5 27.0 37.0 67.8 - 38.1 51.4 66.4
54.5 S 33.2
basis (wt%)
27
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Example 6 - Evaluation of Medium Vacuum Gas Oils (MVGO) Fractions Derived from
Atmospheric
Resid Feed AR3
[0099] Samples of atmospheric resid feed sample AR3 were evaluated to
provide medium grade
vacuum gas oils (MVGO) for use in producing group III/III+ base oils. The MVGO
samples were
derived from the corresponding AR3 samples as distillation cuts in the 725-895
F range, designated
as MVG03b (broad temperature range cut), and 725-855 F, designated as MVG03n
(narrow
temperature range cut).
[00100] Table 6 presents the results using the MVG03b and MVG03n feeds to
produce group III
4c5t base oils using the process configuration of FIG. 3a. Properties for the
comparative vacuum gas
oil (VGO) are also included. Both MVGO feeds MVG03b and MVG03n provided
increased waxy
Group III product yield for 4 cSt base oil production, with the broad cut
MVG03b showing a
4.5 lvol.% and the narrow MVGO cut MVG03n showing a 6.6 lvol.% increase
compared against the
use of the vacuum gas oil (VGO) feed.
Table 6 - MVGO Use for Group III 4 cSt Base Oil Production
Feed VGO MVG03b MVG03n
Sample ID 2326 2365 2366
Run ID 70-562-1370-1394 70-562-4346-4370 70-562-
4922-4946
R1 Temperature ( F) 720 720 720
R1 Temperature ( F) 740 740 740
Overall LHSV (hr-1) 0.55 0.55 0.55
Pressure (psig) 2025 2050 2025
H2 Average Pressure 1846
1777 1810
(psia)
Recycle Gas (SCF/B) 4482 4550 4461
No Loss Product Yields: Wt. % Vol.% Wt. % Vol.% Wt. %
Vol.%
C5-180 F 3.5 4.8 5.9 7.9 3.9 5.2
180-550 F 39.6 45.4 46.6 52.2 45.3 50.5
550-700 F 22.9 24.5 17.0 17.8 17.6 18.3
700- EP F 31.7 33.8 28.8 30.0 31.4 32.6
Total C4- F 2.0 2.7 2.8
Total C5+ F 97.7 108.4 98.3 107.9 98.2 106.6
H2 Consumption
1281 758 718
(CHEM)(SCF/B)
Mass Closure, wt.% 99.6 99.6 99.7
C3B Viscosity, 100 C (cSt) 4.071 3.996 3.774
C3B Viscosity, 70 C (cSt) 7.462 7.307 6.822
C3B Viscosity Index, VI 137 136 135
Actual waxy yield, C3B, of
18.2 22.7 24.8
feed (lvol%)
Average CAT ( F) 730 730 730
28
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Example 7 - Evaluation of Heavy-Heavy Vacuum Gas Oil (HHVGO) Fractions Derived
from
Atmospheric Resids (AR) to Produce Group II Base Oils
[00101] As noted in Example 5, samples of atmospheric resid (AR) were used
to provide medium
grade vacuum gas oils (MVGO) for use in producing group III/III+ base oils.
The remaining fraction,
absent the MVGO fraction, was designated as an HHVGO fraction. These HHVGO
fractions were
evaluated for use as feed components blended with vacuum gas oils (VGO) to
produce Group II base
oils.
[00102] Table 7a presents the properties of the HHVGO samples HHVG02,
HHVG04, and
HHVG05 and blend of 9%HHVGO/VG0 and 9%HHVGO/VG0. Properties of the comparative
VG0
feed are also shown.
Table 7a - Properties of HHVGO Fractions and HHVGO/VG0 blends
9% __________________________________________________ 9%
Feed VG0 HHVG02 HHVG02 HHVG04 HHVG04 HHVG05
Sample ID: 2358 3107 3574 3187 3915 4109
Yield from Feed Source
100 44.8 40.4 42.4
(vol.%)
API Gravity 18 31.5 19 27.8 18.9 28.8
density (g/m1) 0.9113 0.8261 0.9045 0.8528 0.9057
0.8473
Temperature ( C) 70 80 70 70 70 70
Viscosity Index, VI (D2270) 52 N/A 62 114 99
Viscosity, 100 C (cSt) 13.23 15.19 13.42
20.59 18.18
Viscosity, 70 C (cSt) 37.56 37.34 53.83 48.68
Hot C7 Asphaltenes (wt.%) 0.008 0.0402 0.0152
0.0534 0.0517
Low Level N (ppm) 1620 138 1600 670 1350 498
S (ppm) 31420 1037 27950 3485 28920 826
H by NMR 11.82 11.81 13.54
Micro carbon residue
(wt.%) 0.47 1.63 0.92
Dewaxed Oil (DWO):
Viscosity Index, VI
31 101 37 90 91
(D2270)
Viscosity, 100 C (cSt) 250 16.91 15.15 26.15
21.53
Viscosity, 40 C (cSt) 14.94 177.5 245.9 387.9
282.7
Wax content (wt.%) 6.9 43.4 9.9 29.9 21.8
VI droop from SDW 21 25 24 8
SIMDIST TBP (wt.%), F
0.5% 577 849 602 855 591 844
5% 700 884 713 885 711 876
10% 744 900 755 900 755 891
20% 793 926 803 926 803 915
30% 824 949 836 949 837 937
40% 853 976 866 977 869 960
50% 882 1004 894 1008 898 987
29
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60% 911 1036 923 1044 928 1018
70% 941 1072 952 1086 959 1055
80% 975 1118 987 1141 997 1102
90% 1017 1189 1033 1222 1052 1170
95% 1048 1253 1068 1294 1114 1223
99.5% 1115 1383 1236 1371 1370 1334
[00103] Table 7b
presents the results using the HHVGO/VG0 blend feeds to produce group II
base oils using the process configuration of FIG. 5. Results for the
comparative vacuum gas oil (VGO)
are also included. The results are further summarized in Table 7c. Both HHVGO
feeds, i.e.,
9% HHVG02/VG0 and 9% HHVG04/VG0, provided comparable waxy Group II base oil
product yields
compared with the use of the VG0 feed by itself. The combination of using an
MVGO cut to produce
a Group III base oil and of using the remaining HHVGO fraction to produce a
Group II base oil
therefore provides technical and economic advantages compared with the use of
a vacuum gas oil
feed.
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Table 7b - Waxy Base Oil Yields from HHVGO/VG0 Blend Feeds
Feed VGO 9%
HHVG02/VG0
Sample ID 2358 3574
911-176-4560- 911-176-4368- 911-176-3984-
Run ID 4776 4536 4272 601-63-2397 601-63-
2229
R1 Temperature ( F) 730 717 709 718 708
R2 Temperature ( F) 750 737 729 738 728
LHSV (hr 1) 0.5 0.5 0.5 0.5 0.5
Total Pressure (psig) 1845 1827 1835 1850
1850
Gas Rate (SCFB) 4407 4405 4408 4387 4385
No Loss Yields (wt.%):
Cl 0.3 0.2 0.2 0.2 0.2
C2 0.3 0.2 0.2 0.2 0.2
C3 0.5 0.4 0.3 0.4 0.3
i-C4 0.2 0.1 0.1 0.1 0.1
n-C4 0.5 0.4 0.3 0.4 0.3
C5-180 F 2.1 1.5 1.1 1.5 1.1
180-250 F 1.9 1.0 0.7 1.6 1.1
250-550 F 19.6 13.7 10.4 16.2 12.7
550-737 F 23.5 22.2 20.9
550-749 F 22.6 21.5
737 F+ 49.1 58.3 63.6
749 F+ 54.7 60.3
C5+ 96.3 96.6 96.7 96.7 96.8
Synthetic Conversion
55.9 45.9 40.0
737 F- (wt.%)
Synthetic Conversion
49.9 43.7
749 F- (wt.%)
Mass Closure (wt.%) 99.4 99.6 99.2 99.5 99.2
V30 Results:
Viscosity Index, VI
83 73
(D2270)
Viscosity, 40 C, (cSt) 19.74 21.51
Viscosity, 100 C, (cSt) 3.904 4.041
V3B Results:
Viscosity Index, VI 117 111
Viscosity, 100 C, (cSt) 8.985 9.505
Viscosity, 70 C (cSt) 20.08 21.73
STO API 34.9 33.3
Average CAT ( F) 740 727 719 728 718
Waxy Product Yield: W220 W600 W220 W600 W220 W600
W220 W600 W220 W600
Rate, 40 KBPD feed basis
18.6 8.45 4.7 18.92 14.92 15.52 16.97
8.98 14.72 13.09
(KBPD)
Kinematic Viscosity,
6.064 11.799 6.396 11.801 6.397 11.802 6.316 11.799 6.366 11.802
KV100 (cSt)
Viscosity Index, VI
114 122 86 102 92 103 111 118 104
113
(D2270)
Noack Volatility, (wt.%) 11.5 0.9 14.1 3 13 1.8 11.9
1.6 12.7 2.1
Yield on feed basis
46.5 21.1 11.8 47.3 37.3 38.8 42.4 22.5
36.8 32.7
(vol.%)
31
CA 03150737 2022-02-09
WO 2021/028839 PCT/IB2020/057559
Table 7b (continued) - Waxy Base Oil Yields from HHVGO/VG0 Blend Feeds
Feed VGO 9%
HHVG04/VG0
Sample ID 2358 3915
911-176-4560- 911-176-4368- 911-176-3984- 911-177-
6218- 911-177-5714-
Run ID
4776 4536 4272 6434 5954
R1 Temperature ( F) 730 717 709 733 723
R2 Temperature ( F) 750 737 729 753 743
LHSV (hr 1) 0.5 0.5 0.5 0.5 0.5
Total Pressure (psig) 1845 1827 1835 1847
1841
Gas Rate (SCFB) 4407 4405 4408 4404 4402
No Loss Yields (wt.%):
Cl 0.3 0.2 0.2 0.2 0.2
C2 0.3 0.2 0.2 0.3 0.2
C3 0.5 0.4 0.3 0.4 0.4
i-C4 0.2 0.1 0.1 0.2 0.1
n-C4 0.5 0.4 0.3 0.5 0.4
C5-180 F 2.1 1.5 1.1 2.2 1.4
180-250 F 1.9 1.0 0.7 1.6 1.0
250-550 F 19.6 13.7 10.4 18.1 13.7
550-737 F 23.5 22.2 20.9
550-746 F 23.0 22.5
737 F+ 49.1 58.3 63.6
746 F+ 51.8 58.4
C5+ 96.3 96.6 96.7 96.8 97.0
Synthetic Conversion
55.9 45.9 40.0
737 F- (wt.%)
Synthetic Conversion
52.8 45.6
746 F- (wt.%)
Mass Closure (wt.%) 99.4 99.6 99.2 99.1 98.8
V30 Results:
Viscosity Index, VI
(D2270)
Viscosity, 40 C, (cSt)
Viscosity, 100 C, (cSt)
V3B Results:
Viscosity Index, VI
Viscosity, 100 C, (cSt)
Viscosity, 70 C (cSt)
STO API
Average CAT ( F) 740 727 719 743 733
Waxy Product Yield: W220 W600 W220 W600 W220 W600
W220 W600 W220 W600
Rate, 40 KBPD feed basis
18.6 8.45 4.7 18.92 14.92 15.52 16.71
8.07 14.83 12.49
(KBPD)
Kinematic Viscosity,
6.064 11.799 6.396 11.801 6.397 11.802 6.209 11.799 6.247 11.801
KV100 (cSt)
Viscosity Index, VI
114 122 86 102 92 103 112 120 104
112
(D2270)
Noack Volatility, (wt.%) 11.5 0.9 14.1 3 13 1.8 11.5
1.2 12.4 1.6
Yield on feed basis
46.5 21.1 11.8 47.3 37.3 38.8 41.8
20.2 37.1 31.2
(vol.%)
32
CA 03150737 2022-02-09
WO 2021/028839
PCT/IB2020/057559
Table 7c - Yield Comparison for HHVGO/VG0 Blend Feeds at 109 VI W220
Feed VG0 9% HHVG02/VG0 9% HHVG04/VG0
Sample ID 2358 3574 3915
W220 Viscosity Index, VI 109 109 109
W220 yield (vol.%) 40.3 40.9 40.0
W600 yield (vol.%) 25.8 25.4 24.3
Total waxy yield (vol. %) 66.1 66.3 64.3
Average CAT (T) 738 725 739
[00104] The foregoing description of one or more embodiments of the
invention is primarily for
illustrative purposes, it being recognized that variations might be used which
would still incorporate
the essence of the invention. Reference should be made to the following claims
in determining the
scope of the invention.
[00105] For the purposes of U.S. patent practice, and in other patent
offices where permitted, all
patents and publications cited in the foregoing description of the invention
are incorporated herein
by reference to the extent that any information contained therein is
consistent with and/or
supplements the foregoing disclosure.
33
