Note: Descriptions are shown in the official language in which they were submitted.
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PROCESS FOR MAKING HEAVY GRADE BASE OIL PRODUCTS
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority to U.S. Provisional
Appl. Ser. No. 63/141,955,
filed on January 26, 2021, the disclosure of which is herein incorporated in
its entirety.
FIELD OF THE INVENTION
[0002] The invention concerns a process for making a heavy grade base oil
product by combining
an atmospheric resid feedstock with a base oil feedstock to form a combined
feedstream and forming a
heavy grade 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 ll 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 and yield. 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 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] Extra-heavy higher grades of base oils cannot typically be
economically made using
conventionally available crudes, in part because such feedstocks do not
usually contain sufficient
amounts of molecular species useful to produce such heavy grades. The end
point of typical vacuum gas
oil (VGO) feed cuts used to make heavy neutral (HN) base oils is only 1050 to
1100 F, with base oil
products limited to viscosities in the 11 to 12 cSt range (measured at 100 C).
The molecules required to
make heavier grades of base oils, are not present in significant amounts in
these typically available feed
cuts. Processing such feeds to produce heavier cuts would introduce excessive
amounts of heteroatoms
(such as nitrogen) and aromatics and require extensive pretreatment and high-
severity conversion. The
resulting low yields would make such a process uneconomical using typically
available feeds. As such, a
process utilizing feeds that are suitable to produce heavier grades of base
oils, e.g., feeds that are of
higher purity, lower aromatics content and higher VI in the high boiling range
of interest would be
desirable as sources to produce heavy base oil products.
[0007] Despite the progress in producing base oils from differing and
challenging feeds, a
continuing need therefore exists for improved processes to both utilize
different feedstocks and to
increase the yield of valuable heavier grade base oil products.
SUMMARY OF THE INVENTION
[0008] The present invention is directed to a process for making a base oil
product, particularly a
heavy grade base oil product through hydroprocessing of a base oil feedstream.
While not necessarily
limited thereto, one of the goals of the invention is to provide increased
base oil yield of an extra-heavy
grade base oil product.
[0009] In general, a first process according to the invention comprises
making a base oil by
providing an atmospheric resid feedstock, optionally combined with a
conventional base oil feedstock,
as 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
hydrodewaxing catalyst under
hydroisomerization conditions, to produce a dewaxed product; and, optionally,
contacting the dewaxed
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product with a hydrofinishing catalyst under hydrofinishing conditions to
produce a hydrofinished
dewaxed product. The process produces at least one base oil product comprising
a heavy base oil
product 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. In some aspects, the process may also provide a beneficial yield
improvement for one or more
base oil products as compared with the use of a feedstock that does not
include an atmospheric resid
feedstock component.
[0010] The invention also relates to a method for modifying a base oil
process through the addition
of an atmospheric resid feedstock to a base oil feedstock in a conventional
base oil process that
comprises subjecting a base oil feedstream to hydrocracking and dewaxing steps
to form a dewaxed
product comprising a light product and a heavy product. As such, the modified
base oil process
comprises combining an atmospheric resid feedstock and a base oil feedstock to
form a base oil
feedstream; contacting the base oil feedstream with a hydrocracking catalyst
under hydrocracking
conditions to form a hydrocracked product; separating the hydrocracked product
into at least a gaseous
fraction and a liquid fraction; contacting the liquid fraction with a
hydrodewaxing catalyst under
hydroisomerization conditions, to produce a dewaxed product; and, optionally,
contacting the dewaxed
product with a hydrofinishing catalyst under hydrofinishing conditions to
produce a hydrofinished
dewaxed product. The 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 yield improvements
for one or more base oil
products as compared with the use of a feedstock that does not include an
atmospheric resid feedstock
component.
[0011] The invention further relates to a process for making a heavy base
oil having a viscosity
of at least about 13 cSt at 100 C by separating a base oil feedstream
comprising an atmospheric resid
feedstock, and, optionally, a base oil feedstock into 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 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
hydrocracked product;
separating the hydrocracked product into a gaseous fraction and a liquid
fraction; hydrodewaxing the
liquid fraction to produce a dewaxed product; and optionally, hydrofinishing
of the dewaxed product to
produce a hydrofinished dewaxed product. The process produces at least one
base oil product
comprising a heavy base oil product 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 as compared with the use of a feedstock
that does not include an
atmospheric resid feedstock component.
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[0012] The invention further provides a process for making a base oil
product from the
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, 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] 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.
[0014] FIG. 1 is a general block diagram schematic illustration of a prior
art process to make a base
oil product.
[0015] FIG. 2a is a general block diagram schematic illustration of an
embodiment of a process to
make a base oil product using an atmospheric resid (AR) or a blend of vacuum
gas oil (VGO) and AR
(VGO/AR) according to the invention.
[0016] FIG. 2b is a general block diagram schematic illustration of an
embodiment of a process to
make a Group 111/111+ base oil product using a medium vacuum gas oil (MVGO)
fraction from an
atmospheric resid and a heavy base oil product using a heavy vacuum gas oil
(HVGO) residual fraction
from an atmospheric resid or a blend of VG0 and HVGO (VGO/HVG0) according to
the invention.
DETAILED DESCRIPTION
[0017] 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.
[0018] 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
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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.
[0019] "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)
,,-) cY
..:' ..:'
Group +.; v.-
¨ >:¨
Composition a)
+..
+.. >
._ +..
= >:
.+.. .3 o
0_
Designation ,_-- co vi , * ci_
. c
c '5 C: ' 0 X +7
0 (1.) co co
v.
+.. +.; v 1 -0 TD TD 0 co
L/ (531 5 1
1 .
: . .
. .
I Group I 100
Distilled, solvent refined, 1 >0.03 1 and/or 80-119 l===' 15-20 1
med- i -5 to i
= 1 >10% aromatics 1 <90 1
l high 1 15 1
I Distilled, solvent refined, 1
I 1 and 10 t
1
Group II 1 hydrocracked, <10% 1 (:).03 1 >90 II 80-119 I 10-15 I
med l - -20o l 170
I I I
i aromatics i
I Distilled, solvent refined, 1 ..===
. ..===
.
= = . = = .
Group III I severely hydrocracked, I (:).03 1 and 11 >120 I
5-15 I med 1 -10 to 1 190
I I I >90 1 I 25
I <10% aromatics
I Group III oils additionally 1
I .
:
: .
:
: =
I hydroisomerized, or . . I -15 to I
Group III+ l otherwise processed, <1% 1 -- 1 -- I >130
I I low I _30 I 200
I
I aromatics
..., t ==1 t= "I ...1 1 (...
,
I Polyalphaolefins (PAO) 1
I
I 100% catalytically = l= i=
Group IV I synthesized from olefins 1 -- 1 -- l 135-140
1 1.8 1 low 1 -53 1 270
Iderived from thermally 1
= = = . . . . .
i cracking wax :
= . : = = . = = . =
= . :
:
I 100% catalytically
I synthesized by reacting
. . . .
Group V 1 acids and alcohols; All 1 -- 1 -- I 140
I 1.0 I high I -21 I 260
I base oils not included in I
1 Groups I-IV
I
= I
= I
= I
= I
= I
=
[0020] "API gravity" refers to the gravity of a petroleum feedstock or
product relative to water,
as determined by ASTM D4052-11 or ASTM D1298, typically performed using
commercially available
petroleum analysis equipment.
[0021] "ISO-VG"
refers to the viscosity classification that is recommended for industrial
applications, as defined by 1503448:1992.
[0022] "Viscosity index" (VI) represents the temperature dependency of a
lubricant, as
determined by ASTM D2270-10(E2011) , typically performed using commercially
available petroleum
analysis equipment.
[0023] "Micro-Carbon Residue" (MCRT) represents the amount of carbon
residue formed as
determined by ASTM D4530, typically performed using commercially available
petroleum analysis
equipment.
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[0024] "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.
[0025] "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.
[0026] "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.
As used herein the term "medium vacuum gas oil", abbreviated as "MVGO" refers
to a vacuum gas oil,
or a portion thereof, including, e.g., wherein the MVGO is a vacuum gas oil,
or a portion thereof,
having a front end cut point of about 700 F or greater and a back end cut
point of about 900 F or
less. The term "heavy vacuum gas oil", abbreviated as "HVGO", refers to a
heavy vacuum gas oil, or a
portion thereof, including, e.g., a fraction derived from a VG0. In some
cases, HVGO may be derived
from a VG0 feedstock in which an MVGO cut portion has been separated from the
VG0 feedstock,
leaving the remainder as the HVGO portion. For example, the heavy vacuum gas
oil (HVGO) may be the
remainder obtained from a VG0 feedstock in which an MVGO portion has been
removed, the MVGO
portion having a front end cut point of about 700 F or greater and a back end
cut point of about
900 F or less.
[0027] "Deasphalted oil" (DAO) 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.
[0028] "Treatment," "treated," "upgrade," "upgrading" and "upgraded," when
used in conjunction
with an oil feedstock, describes a feedstock that is being or has been
subjected to hydroprocessing, or a
resulting material or crude product, having a reduction in the molecular
weight of the feedstock, a
reduction in the boiling point range of the feedstock, a reduction in the
concentration of asphaltenes, a
reduction in the concentration of hydrocarbon free radicals, and/or a
reduction in the quantity of
impurities, such as sulfur, nitrogen, oxygen, halides, and metals.
[0029] "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.
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[0030] "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.
[0031] "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.
[0032] "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.
[0033] "Catalytic dewaxing", or hydroisomerization, refers to a process in
which normal paraffins
are isomerized to their more branched counterparts in the presence of hydrogen
and over a catalyst.
[0034] "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.
[0035] The term "Hydrogen" or "hydrogen" refers to hydrogen itself, and/or
a compound or
compounds that provide a source of hydrogen.
[0036] "Cut point" refers to the temperature on a True Boiling Point (TBP)
curve at which a
predetermined degree of separation is reached.
[0037] "TBP" refers to the boiling point of a hydrocarbonaceous feed or
product, as determined
by Simulated Distillation (SimDist) by ASTM D2887-13.
[0038] "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).
[0039] "Group IIB" or "Group 1113 metal" refers to zinc (Zn), cadmium (Cd),
mercury (Hg), and
combinations thereof in any of elemental, compound, or ionic form.
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[0040] "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.
[0041] "Group V metal" refers to vanadium (V), niobium (Nb), tantalum (Ta),
and combinations
thereof in their elemental, compound, or ionic form.
[0042] "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.
[0043] "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.
[0044] 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 aluminates, zeolites, alumina-boria, silica-alumina-
magnesia, silica-alumina-titania
and materials obtained by adding other zeolites and other complex oxides
thereto.
[0045] "Molecular sieve" refers to a material having uniform pores of
molecular dimensions within
a framework structure, such that only certain molecules, depending on the type
of molecular sieve, have
access to the pore structure of the molecular sieve, while other molecules are
excluded, e.g., due to
molecular size and/or reactivity. Zeolites, crystalline aluminophosphates and
crystalline
silicoaluminophosphates are representative examples of molecular sieves.
[0046] W220 and W600 refer to waxy medium and heavy Group ll 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
API Base Stock Category (API 1509 E.1.3) Group II Group
II
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
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Flash Point, COC, C ASTM D92 230 265
Color ASTM D1500 L0.5 L0.5
Sulfur, ppnn Chevron <6 <6
Water, ppnn ASTM D1744 <50 <50
Saturates, HPLC, wt % Chevron >99 >99
Aromatics, HPLC, wt % Chevron <1 <1
[0047] 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.
[0048] 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.
[0049] 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.
[0050] In one aspect, the present invention is a process for making a base
oil, which is useful for
making a heavy base oil having a viscosity of at least about 13 cSt at 100 C,
comprising contacting a base
oil feedstream 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 of at least about
13 cSt at 100 C.
[0051] 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 5-50 cSt or 5-80 wt.% or 5-70 wt.% or 5-60
wt.% or 5-50 wt.% or
5-40 wt.% or 5-30 wt.% or 5-20 cSt or 5-15 cSt, or at least 5cSt, or at least
6 cSt;
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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 5-90 wt.% or 5-80 wt.% or 5-70 wt.% or 5-60 wt.%
or 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.%, or,
optionally, less than the wax content of the atmospheric resid feedstock;
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 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 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; and/or
1050+ F content of less than 10 wt.%, or less than 8 wt.%, or less than 7
wt.%, or less than 6 wt.%,
or less than 5 wt.%, or less than 4 wt.%, or less than 3 wt.%, or less than 2
wt.%, or in the range of
2-15 wt.% or 2-10 wt.% or 1-7 wt.%, optionally, less than the 1050+ F content
of the atmospheric
resid feedstock.
[0052] In some aspects, the base oil feedstock 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 in the
range of 1000-5000
ppm, or 2000-5000 ppm, or 1000-4000 ppm, or 1000-3000 ppm; or 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 1000-30000 ppm or 1000-25000 ppm or 1000-15000 ppm or 1000-
10000 ppm;
or a 1050+ F content of less than 10 wt.%, or less than 8 wt.%, or less than 7
wt.%, or less than 6
wt.%, or less than 5 wt.%, or less than 4 wt.%, or less than 3 wt.%, or less
than 2 wt.%, or in the
range of 2 -15 wt.% or 2-10 wt.% or 1-7 wt.%, optionally, less than the 1050+
F content of the
atmospheric resid feedstock, or a combination thereof.
[0053] 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, including whole crudes, and paraffin-based
crudes.
[0054] The atmospheric resid (AR) feedstock generally meets one or more of
the following
property conditions:
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API gravity in the range of 20-60 or 20-45 or 25-45, or at least 20, or at
least 22, or, optionally,
greater than the API of the base oil feedstock;
VI in the range of 50-200, or 70-190, or 90-180, or at least 80, or,
optionally, greater than the
VI of the base oil feedstock;
viscosity at 100 C in the range of 3-30 cSt, or 3-25 cSt, or 3-20 cSt, or 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 5cSt,
or at least 6 cSt;
hot C7 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 wt. %, or less than about 0.2
wt.%, or less than about
0.1 wt.%;
wax content in the range of 5-90 wt.%, or 5-80 wt.%, or 5-70 wt.%, or 5-60
wt.%, or 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.%, 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 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
100-2000 ppm,
or 100-1000 ppm, or 100-500 ppm, or 100-200 ppm; and/or
1050+ F content in the range of 2-50 wt.%, 2-40 wt.%, or 4-50 wt.%, or 4-40
wt.%, or 8-50
wt.%, or 8-40 wt.%, or up to 50 wt.%, or up to 40 wt.%, or up to 30 wt.%, or
up to 20 wt.%, or up to
wt.%, optionally, greater than the 1050+ F content of the base oil feedstock.
[0055] 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.
[0056] The atmospheric resid (AR) feedstock generally differs from
conventional AR feedstocks.
For example, the AR feedstock typically differs in one of more of the
foregoing feedstock properties
from conventional AR feedstocks, with AR feedstocks useful in the invention
having generally lower
property values and ranges. In more particular cases, as compared with
conventional AR's, the AR
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feedstock has lower hot C7 asphaltene content, nitrogen and/or sulfur content,
1050+ F content,
metals content (e.g., Nickel, Vanadium, and/or Iron), or a combination
thereof.
[0057] In some cases, the atmospheric resid feedstock has a hot 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 a hot 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 a metals content
of: less than about 5
ppm Nickel, or less than about 3 ppm Vanadium, or less than about 4 ppm Iron,
or a combination
thereof. Still further, the AR feedstock may also meet the following
conditions: the atmospheric resid
feedstock meets the following conditions: viscosity at 100 C of less than
10cSt, or in the range of
3-10 cSt; hot C-7 asphaltene content of less than about 0.1 wt.%, or in the
range of about 0.01-0.1 wt.%;
MCRT of less than 2 wt.%; nitrogen content of less than 800 ppm; sulfur
content of less than 3000 ppm;
Nickel content of less than 5 ppm; Vanadium content of less than 3 ppm; and
Iron content of less than
4 ppm.
[0058] 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.
[0059] The base oil feedstream generally comprises 5-95 wt.% atmospheric
resid feedstock
and 95-5 wt.% base oil feedstock, or 10-90 wt.% atmospheric resid feedstock
and 90-10 wt.% base
oil feedstock, or 10-80 wt.% atmospheric resid feedstock and 90-20 wt.% base
oil feedstock, or
10-60 wt.% atmospheric resid feedstock and 90-40 wt.% base oil feedstock, or
10-50 wt.%
atmospheric resid feedstock and 50-90 wt.% base oil feedstock, or 10-40 wt.%
atmospheric resid
feedstock and 90-60 wt.% base oil feedstock, or 10-30 wt.% atmospheric resid
feedstock and 90-70
wt.% base oil feedstock, or 30-60 wt.% atmospheric resid feedstock and 70-40
wt.% base oil
feedstock, or 40-60 wt.% atmospheric resid feedstock and 60-40 wt.% base oil
feedstock.
[0060] 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. While some of the particular property characteristics of
the base oil feedstock
and the AR feedstock may have similar or overlapping property values or ranges
of values, the base
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oil feedstock and the AR feedstock are not the same since typically one or
more 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 a combination thereof.
[0061] 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 used, however.
[0062] The base oil feedstock may comprise vacuum gas oil, or consist
essentially of vacuum
gas oil, or consist of vacuum gas oil, including whole uncut feedstocks and
cut feedstocks. The
vacuum gas oil may be a heavy vacuum gas oil obtained from vacuum gas oil that
is cut into a light
fraction and a heavy fraction, with the heavy fraction having a cut point
temperature range of
about 950-1050 F. The VG0 may be a blend derived from various feedstocks, as
well, and may
include defined boiling point range components in differing amounts. For
example, one component
of the VG0 derived from a particular feedstock may have a higher 1050+ F
content while other
VG0 components contribute lower 1050+ F content to the VG0.
[0063] 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 about 3-9 cSt, or 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 13-24 cSt or
13-21 cSt or 13-18 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 13 cSt or
greater at 100 C, or 13-16.5 cSt at 100 C, or about 13-23 cSt at 100 C, or a
combination thereof.
[0064] 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 0.5 liquid volume %
(Lvol.%), or at least about 1 Lvol.%, or at least about 2 Lvol.%, or at least
about 5 Lvol.% 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 oil product may
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.%, compared
with the same process
that does not include the atmospheric resid feedstock in the base oil
feedstream. The total waxy
yield may also be increased by at least about 0.5 Lvol.%, or at least about 1
Lvol.%, or at least about 2
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Lvol.%, or at least about 5 Lvol.% compared with the same process that does
not include the
atmospheric resid feedstock in the base oil feedstream.
[0065] In another aspect, the invention concerns a method for modifying a
conventional or
existing base oil process to produce a heavy base oil product, particularly 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. 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 subjecting a base oil feedstock
comprising
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.
[0066] The invention further relates to a process for making 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
feedstream, or a fraction thereof, comprising providing a base oil feedstream
comprising an
atmospheric resid feedstock, and, optionally, a base oil feedstock separating
the base oil feedstream
into 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 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 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, such that the process produces at least one heavy base oil product
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.
[0067] 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 0.5 Ivol.%, or
1 Ivol.%, or 2 Ivol.%, or 3 Ivol.%, or 5 !vol.% greater than the same process
that does not include the
MVGO as the base oil feedstock.
[0068] 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 MVGO 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
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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 HVGO fraction; using the HVGO
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, while also producing at least one heavy base oil
product 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.
[0069] 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.
[0070] Advantageously, the fractionation of the AR feedstock into MVGO and
HVGO fractions
provides the ability to produce Group 111/111+ base oil product while still
allowing the HVGO fraction to be
used with a conventional VG0 base oil feedstock to produce a heavy grade base
oil product, particularly
a heavy base oil product 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. For example, Group 111/111+ products that may be
produced include a base oil
product having a viscosity of about 4 cSt at 100 C (e.g., 3-5 cSt at 100 C).
In some embodiments, the use
of MVGO to produce Group 111/111+ base oil product results in greater yields
of such products.
[0071] 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 (HVGO), with the MVGO fraction feedstream being used to
produce a Group 111/111+
base oil product and the HVGO fraction feedstream being combined with a
conventional VG0 base oil
feedstock to produce a heavy base oil product.
[0072] 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;
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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. Suitable catalysts generally include supported
catalysts, i.e., those
catalysts comprising one or more supports as described herein and as known in
the art. Unsupported or
bulk catalysts, e.g., mixed metal sulfide catalysts as may be described in US
2015/0136646, need not
generally be used in the present process.
[0073] 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.
[0074] 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 hil- to 15 hil- (v/v),
e.g., from 0.25 hr-1- to 2.5 hr'; a hydrogen feed rate, in terms of
Hz/hydrocarbon ratio, of from 500
SCF/bbl to 5000 SCF/bbl (89 to 890 m3 1-12/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.
[0075] 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 heteroatom content, and to
reduce the amount of low
boiling components in the dewaxer feed. Some dewaxing catalysts accomplish the
wax conversion
reactions by cracking the waxy molecules to lower molecular weight molecules.
Other dewaxing
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processes may convert the wax contained in the hydrocarbon feed to the process
by wax isomerization,
to produce isomerized molecules that have a lower pour point than the non-
isomerized molecular
counterparts. As used herein, isomerization encompasses a hydroisomerization
process, for using
hydrogen in the isomerization of the wax molecules under catalytic
hydroisomerization conditions.
[0076] Dewaxing generally includes processing the dewaxer feedstock by
hydroisomerization to
convert at least the n-paraffins and to form an isomerized product comprising
isoparaffins. Suitable
isomerization catalysts for use in the dewaxing step can include, but are not
limited to, Pt and/or Pd on
a support. Suitable supports include, but are not limited to, zeolites CIT-1,
IM-5, SSZ-20, SSZ-23, SSZ-24,
SSZ-25, SSZ-26, SSZ-31, SSZ-32, SSZ-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 zeolites,
FAU-type zeolites, FER-type zeolites, MEL-type zeolites, MFI-type zeolites,
MIT-type zeolites, MTW-type
zeolites, MWW-type zeolites, MR[-type zeolites, TON-type zeolites, other
molecular sieves materials
based upon crystalline aluminophosphates such as SM-3, SM-7, SAP0-11, SAPO-31,
SAPO-41, MAP0-11
and MAPO-31. Isomerization may also involve a Pt and/or Pd catalyst supported
on an acidic support
material such as beta or zeolite Y molecular sieves, silica, alumina, silica-
alumina, and combinations
thereof. Suitable isomerization catalysts are well described in the patent
literature, see, e.g., US. Pat.
Nos. 4,859,312; 5,158,665; and 5,300,210.
[0077] Hydrodewaxing conditions generally depend on the feed used, the
catalyst used, catalyst
pre-treatment, 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 M Pa
to 20.68 MPa gauge); a LHSV of from 0.25 hr-1- to 20 hr'; and a hydrogen to
feed ratio of from 2000
SCF/bbl to 30,000 SCF/bbl (356 to 5340 m3 H2/m3 feed). Generally, hydrogen
will be separated from the
product and recycled to the isomerization zone. Suitable dewaxing conditions
and processes are
described in, e.g., U.S. Pat. Nos. 5,135,638; 5,282,958; and 7,282,134.
[0078] Waxy products W220 and W600 may be dewaxed to form 220N and 600N
neutral 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 viscometric or Noack target conditions, for particular
base oil grades like 220N and
600N. Isomerization and blending can be used to modulate and maintain pour
point and cloud point of
the base oil at suitable values. Normal paraffins may also be blended with
other base oil components
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prior to undergoing catalytic isomerization, including blending normal
paraffins with the isomerized
product. Lubricating base oils that may be produced in the dewaxing step may
be treated in a
separation step to remove light product. The lubricating base oil may be
further treated by distillation,
using atmospheric distillation and optionally vacuum distillation to produce a
lubricating base oil.
[0079] Typical hydrotreating conditions vary over a wide range. In general,
the overall LHSV is
about 0.25 hi' to 10 hi' (v/v), or alternatively about 0.5 hi' to 1.5 hi'. 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 Hz/hydrocarbon ratio, are typically from 500 SCF/Bbl to 5000
SCF/bbl (89 to 890 m3 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).
[0080] In practice, layered catalyst systems may be used comprising
hydrotreating (HDT, HDM,
DEMET, etc.), hydrocracking (HCR), hydrodewaxing (HDW), and hydrofinishing
(HEN) catalysts to
produce intermediate and/or finished base oils using single or multireactor
systems. A typical
configuration includes two reactors with the first reactor comprising layered
catalysts providing DEM ET,
HDT pretreatment, HCR, and/or HDW activity. Differing catalysts performing
similar functions, e.g.,
different levels of hydrocracking activity, may be used as well, e.g., in
different layers within a single
reactor or in separate reactors.
[0081] For the avoidance of doubt, the present application is directed to
the subject-matter
described in the following numbered paragraphs:
1. A process for making a base oil, which is useful for making 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, comprising
contacting a base oil feedstream 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 of at least about 12.7 cSt, or at least about 13 cSt, or at
least about 13.3 cSt at
100 C.
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2. The method of paragraph 1, which is used to modify a base oil process to
produce 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 comprises subjecting a base oil feedstream to
hydrocracking and
dewaxing steps to form a dewaxed product comprising a light product and a
heavy product; the
method comprising,
subjecting the base oil feedstream comprising the atmospheric resid feedstock
to the
hydrocracking and dewaxing steps of the base oil process;
wherein the modified base oil process comprises:
contacting a base oil feedstream 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 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 modified process produces at least one base oil product 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.
3. A process for making 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 feedstream, or a
fraction thereof, according
to paragraph 1, the process comprising
providing a base oil feedstream comprising an atmospheric resid feedstock,
and, optionally, a base
oil feedstock;
separating the base oil feedstream, or a fraction thereof, into a vacuum gas
oil 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 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 one of paragraphs 1-3, wherein the base oil feedstream
includes a base oil
feedstock.
5. The process of any one of paragraphs 1-4, wherein the atmospheric resid
feedstock meets one or
more of the following conditions:
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API gravity in the range of 20-60 or 20-45 or 25-45, or at least 20, or at
least 22, or, optionally,
greater than the API of the base oil feedstock;
VI in the range of 50-200, or 70-190, or 90-180, or at least 80, or,
optionally, greater than the VI of
the base oil feedstock;
viscosity at 100 C in the range of 3-30 cSt, or 3-25 cSt, or 3-20 cSt, or 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 5cSt, or at
least 6 cSt;
hot C7 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 wt. %, or less than about 0.2 wt.%, or
less than about 0.1 wt.%;
wax content in the range of 5-90 wt.%, or 5-80 wt.%, or 5-70 wt.%, or 5-60
wt.%, or 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.%, 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 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 100-2000
ppm, or 100-1000
ppm, or 100-500 ppm, or 100-200 ppm; and/or
1050+ F content in the range of 2-50 wt.%, 2-40 wt.%, or 4-50 wt.%, or 4-40
wt.%, or 8-50 wt.%, or
8-40 wt.%, or up to 50 wt.%, or up to 40 wt.%, or up to 30 wt.%, or up to 20
wt.%, or up to 10 wt.%,
optionally, greater than the 1050+ F content of the base oil feedstock.
6. The process of any one of paragraphs 1-5, wherein the atmospheric resid
feedstock has a hot C7
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.
7. The process of any one of paragraphs 1-6, wherein the atmospheric resid
feedstock has a hot C7
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
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than 100 ppm; and a metals content of: less than about 5 ppm Nickel, or less
than about 3 ppm
Vanadium, or less than about 4 ppm Iron, or a combination thereof.
8. The process of any one of paragraphs 1-7, wherein the atmospheric resid
feedstock meets the
following conditions:
viscosity at 100 C of less than 10cSt, or in the range of 3-10 cSt;
hot C7 asphaltene content of less than about 0.1 wt.%, or in the range of
about 0.01-0.1 wt.%;
MCRT of less than 2 wt.%;
nitrogen content of less than 800 ppm;
sulfur content of less than 3000 ppm;
Nickel content of less than 5 ppm;
Vanadium content of less than 3 ppm; and
Iron content of less than 4 ppm.
9. The process of any one of paragraphs 1-8, wherein the base oil feedstock
meets one or more of
the following 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 5-50 cSt or 5-80 wt.% or 5-70 wt.% or 5-60
wt.% or 5-50 wt.% or
5-40 wt.% or 5-30 wt.% 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 5-90 wt.% or 5-80 wt.% or 5-70 wt.% or 5-60 wt.%
or 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.%, or,
optionally, less than the wax content of the atmospheric resid feedstock;
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 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 the
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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; and/or
1050+ F content of less than 10 wt.%, or less than 8 wt.%, or less than 7
wt.%, or less than 6 wt.%,
or less than 5 wt.%, or less than 4 wt.%, or less than 3 wt.%, or less than 2
wt.%, or in the range of
2-15 wt.% or 2-10 wt.% or 1-7 wt.%, optionally, less than the 1050+ F content
of the atmospheric
resid feedstock.
10. The process of any one of paragraphs 1-9, wherein the base oil feedstock
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 in the
range of 1000-5000 ppm, or 2000-5000 ppm, or 1000-4000 ppm, or 1000-3000 ppm;
or 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 1000-30000 ppm or 1000-25000 ppm or 1000-
15000 ppm or
1000-10000 ppm; or a 1050+ F content of less than 10 wt.%, or less than 8
wt.%, or less than 7 wt.%,
or less than 6 wt.%, or less than 5 wt.%, or less than 4 wt.%, or less than 3
wt.%, or less than 2 wt.%, or
in the range of 2-15 wt.% or 2-10 wt.% or 1-7 wt.%, optionally, less than the
1050+ F content of the
atmospheric resid feedstock, or a combination thereof.
11. The process of any one of paragraphs 1-10, wherein the base oil feedstream
comprises
5-95 wt.% atmospheric resid feedstock and 95-5 wt.% base oil feedstock, or 10-
90 wt.%
atmospheric resid feedstock and 90-10 wt.% base oil feedstock, or 10-80 wt.%
atmospheric resid
feedstock and 90-20 wt.% base oil feedstock, or 10-60 wt.% atmospheric resid
feedstock and 90-40
wt.% base oil feedstock, or 10-50 wt.% atmospheric resid feedstock and 50-90
wt.% base oil
feedstock, or 10-40 wt.% atmospheric resid feedstock and 90-60 wt.% base oil
feedstock, or
10-30 wt.% atmospheric resid feedstock and 90-70 wt.% base oil feedstock, or
30-60 wt.%
atmospheric resid feedstock and 70-40 wt.% base oil feedstock, or 40-60 wt.%
atmospheric resid
feedstock and 60-40 wt.% base oil feedstock.
12. The process of any one of paragraphs 1-11, wherein the base oil feedstream
does not contain an
added whole crude oil feedstock, or wherein the base oil feedstream does not
contain a vacuum
residue feedstock, or wherein the base oil feedstream does not contain a
deasphalted oil, or
wherein the base oil feedstream contains only atmospheric resid feedstock and,
optionally, a base
oil feedstock.
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13. The process of any one of paragraphs 1-12, wherein the process does 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.
14. The process of any one of paragraphs 1-13, wherein the atmospheric resid
feedstock and the base
oil feedstock are not the same.
15. The process of paragraph14, wherein the atmospheric resid feedstock and
the base oil feedstock
differ in nitrogen content, sulfur content, 1050+ F content, or a combination
thereof.
16. The process of any one of paragraphs 1-15, wherein the base oil feedstock
comprises vacuum gas
oil or is vacuum gas oil, or consists essentially of vacuum gas oil, or
consists of vacuum gas oil.
17. The process of any one of paragraphs 1-16, wherein the vacuum gas oil is 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.
18. The process of any one of paragraphs 1-17, wherein the dewaxed product
and/or the
hydrofinished dewaxed product is 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 in the
range of 3-9 cSt, or 4-8 cSt or 5-7 cSt at 100 C and/or the heavy base oil
product has a nominal viscosity
in the range of 13-24 cSt, or 13-21 cSt, or 13-18 cSt at 100 C.
20. The process of paragraph 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% compared with the same process that does not
include the
atmospheric resid feedstock in the base oil feedstream.
21. The process of any one of paragraphs 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%
compared with the same process that does not include the atmospheric resid
feedstock in the base oil
feedstream.
22. The process of any one of paragraphs 1-21, wherein the dewaxed product is
further separated into
at least a lighter product having a nominal viscosity in the range of about
5.5 to 7.5 cSt at 100 C or at
least a heavier product having a nominal viscosity of 13 cSt or greater at 100
C, or 13-16.5 cSt at 100 C,
or 18-23 cSt at 100 C, or a combination thereof.
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23. The process of paragraph 3, further comprising
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 hydrofinished dewaxed product
comprises a Group Ill or
Group III+ base oil product having a viscosity index of 120 or greater after
dewaxing.
24. The process of paragraph 23, wherein the dewaxed product and/or the
hydrofinished dewaxed
product comprises a Group Ill or Group III+ base oil product having a
viscosity index of 130 or greater
after dewaxing, or 135 or greater after dewaxing, or 140 or greater after
dewaxing.
25. The process of paragraph 23, wherein the dewaxed product and/or the
hydrofinished dewaxed
product comprises a Group Ill 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 one of paragraphs 1-26, 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 ll base oil product having a nominal viscosity at 100 C in the
range of 13-16.5 cSt.
29. The Group ll base oil product of paragraph 22, where in product is a Grade
800 base oil.
30. A Group ll base oil product having a nominal viscosity at 100 C in the
range of 18-23 cSt.
31. The Group ll base oil product of paragraph 30, wherein the product is a
Grade 900 base oil.
32. The Group ll base oil product of any one of paragraphs 28-31 made in
accordance with the process
of any one of claims 1-27.
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EXAMPLES
[0082] Samples of vacuum gas oil (VGO) and atmospheric resid (AR) were
obtained from
commercially available sources and used in the process scheme illustrated in
FIG. 2a.
[0083] Process conditions used included 0.5 hr-1 LHSV, reactor H2 partial
pressure of 1700-1800
psia, hydrogen feed gas oil (recycle) ratio of about 4500 scfb, and reactor
temperatures in the range of
700-770+ F. Temperature and other process conditions were selected to produce
a light base oil target
product having a VI of about 109 and a viscosity at 100 C of about 6 cSt. The
heavy base oil fraction is
described more specifically in each of the following examples.
[0084] The catalyst loading in each of the reactors according to FIG. 2a
was a conventional scheme
for base oil production as described hereinabove. The catalyst configuration
included layered catalyst
systems comprising layers of base metal hydrodemetalation (demet) catalysts at
the top of the reactor
catalyst bed, followed by base metal hydrotreating catalysts and then by
layers of zeolite-containing
base metal hydrocracking catalysts of increasing activity.
Example 1 - Vacuum Gas Oil (VGO) Feedstock (comparative feedstock)
[0085] A sample of vacuum gas oil (VGO) feedstock from a commercially
available source used to
produce base oil products was obtained and analyzed as a comparative base
case. The VGO feedstock
was used in the following examples according to the process configurations
shown in FIG's 1 and 2a. The
properties of this VGO feedstock (sample ID 2358) are shown in Table 1.
Table 1 - Properties of Vacuum Gas Oil (VGO) Feedstock
Feed VGO
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 (ppnn) 1620
S content (ppnn) 31420
1050+ (wt.%) 4.7
Sinndist ( F)
IBP 525
5% 707
15% 776
20% 795
30% 827
35% 841
40% 855
45% 870
50% 883
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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
[0086]
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
N content (ppnn) 808 70.7 623 340 271
S content (ppnn) 5654 805 3938 2266 558
1050+ F (wt.%) 24.2 8.3 15.6 11.9 14.3
Sinndist ( 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
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[0087] Table 2A provides properties for a comparative conventional AR base
oil process feedstock
component. As may be noted, the AR's shown in Table 2 differ significantly
from ARO shown in Table
2A.
Table 2A - Properties of Representative Conventional Atmospheric Resid (AR)
Feedstock
Feed ARO Sample
Property Property Value
API Gravity 10.7
Viscosity, 100 C (cSt) 123.7
Viscosity, 70 C (cSt) 2030.5
Hot C7 Asphaltenes (wt.%) 9.9
N content (ppnn) 3492
S content (ppnn) 48262
Ni (ppnn) 43.7
V (ppnn) 180.0
MCRT (wt. %) 14.3
Example 3 - Properties of Blends of Atmospheric Resid (AR) Feedstocks with
Vacuum Gas Oil (VGO)
Feedstock
[0088] 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 d AR/VGO Blend (wt/wt) Sample Property Value
45% AR1/ 50% AR2/ 53% AR3/ 20% AR4/ 20% AR5/ 50% AR4/
Propeeerty
55% VGO 50% VGO 47% VGO 80% VGO 80% VGO 50% VGO
Sample ID 2148 2190 2394 3924 4122 7200
API Gravity 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
Hot C7 Asphaltenes (wt.%) 0.0386
wax content (wt.%) 18 8 15
N content (ppnn) 1540 1050 1460 1230 1270 991
S content (ppnn) 20490 15630 26160 26620 25880 17430
1050+ (wt.%) 6.4 6 6.8 7.3 9.3
Sinndist ( F)
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
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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
Resid (AR) Feedstock
with Vacuum Gas Oil (VGO) Feedstock ¨ AR1/VGO Blend
[0089] The
blend feedstock sample of the atmospheric resid AR1 with vacuum gas oil (VGO)
of
example 3 was evaluated for heavy base oil production according to the process
represented by FIG. 2a.
The AR1/VGO feedstock blend (45 wt.% AR1, 55 wt.% VGO) whole liquid product
was distilled into eight
fractions, the heaviest of which had a 911 F cut point. A distillation model
showed a whole liquid
product of 40,000 BPOD hydrocracker feed could be distilled into a product of:
14,460 BPOD waxy heavy neutral base oil product (17.05 cSt at 100 C, VI of
114, 898 F+),
corresponding to 36.2 wt.% of the 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 wt. % of the product; and
27,470 BPOD total waxy base oil products, 754 F+ oils, corresponding to 68.7
wt.% of the liquid
product.
Example 5 ¨Evaluation of Heavy Base Oil Production from Blends of Atmospheric
Resid (AR)
Feedstock with Vacuum Gas Oil (VGO) Feedstock ¨ AR2/VG0 Blend
[0090] The
blend feedstock sample of the atmospheric resid AR2 with vacuum gas oil (VGO)
of
example 3 was evaluated for heavy base oil production according to the process
represented by FIG 2a.
[0091] The base oil total is 56 wt.% of the liquid product. The individual
base oils had the following
properties:
34 wt.% of the liquid product total was waxy 220 neutral base oil product (6.0
cSt at 100 C, VI of
114, 750-905 F);
24 wt.% of the liquid product total was heavy neutral base oil product (12.85
cSt at 100 C, VI of
118. 905 F+).
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Example 6 - Evaluation of Heavy Base Oil Production from Blends of Atmospheric
Resid (AR)
Feedstock with Vacuum Gas Oil (VGO) Feedstock ¨ AR3/VG0 Blend
The blend feedstock sample of the atmospheric resid AR3 with vacuum gas oil
(VGO) of example 3 was
evaluated for heavy base oil production according to the process represented
by FIG 2a. The base oil
total is 56 wt.% of the liquid product. The individual base oils had the
following properties:
34 wt.% of the liquid product total was waxy 220 neutral base oil product (6.0
cSt at 100 C, VI of
108, 750-903 F);
22 wt.% of the liquid product total was 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
Resid (AR)
Feedstock with Vacuum Gas Oil (VGO) Feedstock ¨ 50% AR4/VG0 Blend
The blend feedstock with sample ID 7200, consisting of the atmospheric resid
AR4 combined at 50%
with the vacuum gas oil (VGO) of example 3, was evaluated for heavy base oil
production according to
the process represented by FIG 2a. The base oil total is 68 wt.% of the liquid
product. The individual
base oils had the following properties:
55 wt.% of the liquid product total was waxy 220 neutral base oil product (6.0
cSt at 100 C, VI of
118, 708-977 F);
13 wt.% of the liquid product total was heavy neutral base oil product of high
viscosity (21.12 cSt
at 100 C, VI of 111, 977 F+).
Example 8 - Evaluation of Heavy Base Oil Production from Comparative Feedstock
Using Vacuum Gas
Oil (VGO) Feedstock
[0092] The feedstock sample of vacuum gas oil (VGO) of example 3 was
evaluated for heavy base
oil production according to the process represented by FIG 1. The base oil
total is 48 wt.% of the liquid
product. The individual base oils had the following properties:
27 wt.% of the liquid product total was waxy 220 neutral base oil product (6.0
cSt at 100 C, VI of
109, 750-885 F);
21 wt.% of the liquid product total was heavy neutral base oil product
(11.61cSt at 100 C, VI of
116, 885 F+).
[0093] In the foregoing examples 4 to 7, the heavy neutral base oils have
higher viscosity than the
heavy neutral product made in the comparative base case example 8.
Specifically, the heavier base oil
product made from only VGO (example 8, base case with no AR) does not meet a
target viscosity at
100 C of about 13 cSt. The use of atmospheric resid as a feedstock or
feedstock blend is shown to
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advantageously allow extra-heavy grades of base oils to be made following an
all-hydroprocessing route.
Use of an AR feed component results in higher yields and higher product
quality and allows feed blends
with heavier components and higher end points to be processed. While
variations in the fractionation
targets and conditions may result in base oil products with additional or
different properties, in all cases,
the use of an atmospheric resid feedstock enables production of extra heavy
base oils not generally
attainable by processing typical or standard base oil feedstocks alone.
[0094] 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.
[0095] 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.
