Process embodiments for producing green coke from residual oil comprise introducing residual oil and a solvent mixture into a mixing vessel to produce a feed mixture, the solvent mixture comprising at least one paraffinic solvent with a carbon number from 3 to 8 and at least one aromatic solvent, where the solvent mixture comprises from 0.1 to 10% by volume of aromatic solvent and 90 to 99.9% by volume of paraffinic solvent, passing the feed mixture to a solvent deasphalting unit to produce a deasphalted oil (DAO) fraction and an asphalt fraction, and passing the DAO fraction to a delayed coker to produce the green coke and a delayed coker effluent.

Process embodiments for producing green coke from residual oil comprise introducing residual oil and a solvent mixture into a mixing vessel to produce a feed mixture, the solvent mixture comprising at least one paraffinic solvent with a carbon number from 3 to 8 and at least one aromatic solvent, where the solvent mixture comprises from 0.1 to 10% by volume of aromatic solvent and 90 to 99.9% by volume of paraffinic solvent, passing the feed mixture to a solvent deasphalting unit to produce a deasphalted oil (DAO) fraction and an asphalt fraction, and passing the DAO fraction to a delayed coker to produce the green coke and a delayed coker effluent.

Embodiments provide a method and apparatus for upgrading a hydrocarbon feedstock. According to at least one embodiment, the method includes (a) supplying a hydrocarbon feedstock to an oxidation reactor, where the hydrocarbon feedstock is oxidized in the presence of a catalyst under conditions sufficient to selectively oxidize sulfur compounds present in the hydrocarbon feedstock; (b) separating the hydrocarbons and the oxidized sulfur compounds by solvent extraction; (c) collecting a residue stream that includes the oxidized sulfur compounds; (d) supplying the residue stream to a coker to produce coker gases and solid coke; and (e) supplying spent adsorbent including residual oils from the adsorption column to the coker for disposing the spent adsorbent after completion of an adsorption cycle.

Embodiments provide a method and apparatus for upgrading a hydrocarbon feedstock. According to at least one embodiment, the method includes (a) supplying a hydrocarbon feedstock to an oxidation reactor, where the hydrocarbon feedstock is oxidized in the presence of a catalyst under conditions sufficient to selectively oxidize sulfur compounds present in the hydrocarbon feedstock; (b) separating the hydrocarbons and the oxidized sulfur compounds by solvent extraction; (c) collecting a residue stream that includes the oxidized sulfur compounds; (d) supplying the residue stream to a coker to produce coker gases and solid coke; and (e) recycling at least a portion of the volatile component stream to the oxidation reactor to selectively oxidize sulfur compounds in the volatile component stream, the recycled portion of the volatile component stream comprising at least one of light coker gas oils and heavy coker gas oils.

An integrated process is provided for producing deasphalted oil, high quality petroleum green coke and liquid coker products. An enhanced solvent deasphalting process is used to treat the feedstock to reduce the level of asphaltenes, N, S and metal contaminants and produce a deasphalted oil with reduced contaminants. A coking process is integrated to produce liquid and gas coking unit products, and petroleum green coke.

An integrated process is provided for producing deasphalted oil, high quality petroleum green coke and liquid coker products. An enhanced solvent deasphalting process is used to treat the feedstock to reduce the level of asphaltenes, N, S and metal contaminants and produce a deasphalted oil with reduced contaminants. A coking process is integrated to produce liquid and gas coking unit products, and petroleum green coke.

A retractable center feed injection device can be employed to feed residual oil into a coke drum as part of a delayed coking process. The retractable center feed injection device can include a housing within which the injection nozzle slides between an extended and a retracted position. A feed inlet is positioned on an opposite side of the coke drum from the retractable center feed injection device. When in the extended position, the injection nozzle can couple with the feed inlet and thereby form an extension of the feed inlet into the center of the coke drum. In this way, the residual oil never flows through the housing.

A retractable center feed injection device can be employed to feed residual oil into a coke drum as part of a delayed coking process. The retractable center feed injection device can include a housing within which the injection nozzle slides between an extended and a retracted position. A feed inlet is positioned on an opposite side of the coke drum from the retractable center feed injection device. When in the extended position, the injection nozzle can couple with the feed inlet and thereby form an extension of the feed inlet into the center of the coke drum. In this way, the residual oil never flows through the housing.

Embodiments of a process for producing high grade coke from crude oil residue include at least partially separating, in a solvent extraction unit, the crude oil residue into a deasphalted oil (DAO)-containing stream and an asphaltene containing-stream, producing a pressurized, heated DAO-containing stream, where the pressurized, heated DAO-containing stream, mixing a supercritical water stream with the pressurized, heated DAO-containing stream to create a combined feed stream, introducing the combined feed stream to an upgrading reactor system operating at supercritical temperature and pressure to yield one or more upgrading reactor output streams comprising upgraded product and a slurry mixture, where the slurry mixture comprises sulfur and one or more additional metals. The process also may include calcining the slurry mixture at a temperature of from 700 C. to 1900 C. to produce a product stream comprising the high grade coke.

Embodiments of a process for producing high grade coke from crude oil residue include at least partially separating, in a solvent extraction unit, the crude oil residue into a deasphalted oil (DAO)-containing stream and an asphaltene containing-stream, producing a pressurized, heated DAO-containing stream, where the pressurized, heated DAO-containing stream, mixing a supercritical water stream with the pressurized, heated DAO-containing stream to create a combined feed stream, introducing the combined feed stream to an upgrading reactor system operating at supercritical temperature and pressure to yield one or more upgrading reactor output streams comprising upgraded product and a slurry mixture, where the slurry mixture comprises sulfur and one or more additional metals. The process also may include calcining the slurry mixture at a temperature of from 700 C. to 1900 C. to produce a product stream comprising the high grade coke.