A method for upgrading heavy oil by using a coke production byproduct comprises the steps of: producing a mixed solution by mixing a coke production byproduct and heavy oil; and hydrogenating the mixed solution under a hydrogenation catalyst, wherein the present disclosure is economical and effective by being able to reduce the amount of coke formation and significantly reduce the partial pressure of added hydrogen by using the coke production byproduct as a hydrogen donor.

Systems and methods are provided for solvent deasphalting of steam cracker tar. The resulting deasphalted oil produced from the steam cracker tar can then be hydroprocessed, such as hydrotreated and/or hydrocracked in a fixed bed reactor. The solvent deasphalting can correspond to a mild or trim deasphalting or can correspond to solvent deasphalting at higher solvent to oil ratios. Performing a trim deasphalting can reduce or minimize the amount of deasphalting residue that is formed as a product from the deasphalting process.

Provided is a system to upgrade an input stream of a straight run vacuum residue or a cracked feedstock that includes a vacuum column, a hydrocracking unit, a high lift solvent deasphalting unit, a low lift solvent deasphalting unit, and a bitumen blowing unit or a pitch pelletizing unit, and optionally a hydrotreating reactor. The system and components thereof may pass a distillate and naphtha product, a light ends product, an asphaltene-lean heavy deasphalted oil stream, an asphaltene-rich pitch stream, a light deasphalted oil that is a lube base feed stock, a heavy oil stream, a bitumen and asphalt stream or a solid fuel. Further provided is a process, including introducing a straight run vacuum residue or a cracked feed stock into a system, and operating the system including a step of fractionating, a step of solvent stage deasphalting, and a step of hydrocracking.

Systems and methods are provided for producing upgraded raffinate and extract products from lubricant boiling range feeds and/or other feeds having a boiling range of 400° F. (204° C.) to 1500° F. (816° C.) or more. The upgraded raffinate and/or extract products can have a reduced or minimized concentration of sulfur, nitrogen, metals, or a combination thereof. The reduced or minimized concentration of sulfur, nitrogen, and/or metals can be achieved by hydrotreating a suitable feed under hydrotreatment conditions corresponding to relatively low levels of feed conversion. Optionally, the feed can also dewaxed, such as by catalytic dewaxing or by solvent dewaxing. Because excessive aromatic saturation is not desired, the pressure for hydrotreatment (and optional dewaxing) can be 500 psig (˜3.4 MPa) to 1200 psig (˜8.2 MPa).

The invention concerns with improved and more flexible deasphalting process for production of lube oil base stock as well as feed stock for secondary processes depending on requirement from heavy residual hydrocarbon oil containing saturates, aromatics, resins and asphaltenes etc by contacting the oil with a solvent comprising of hydrocarbon containing two to six carbon atoms, preferably LPG having C3-C4 hydrocarbons and mixture thereof at predetermined deasphalting conditions wherein the yield of deasphalted oil including its quality is controlled by varying the deasphalting conditions including the operating temperature. The yield variations of 15 to 60 wt % is achieved by swinging the temperature by about 10-20° C. within the operative temperature range of 70-130° C. keeping the rest of the operating conditions including solvent to feed ratio same. The LPG solvent can be recovered using supercritical mode of operation using technology known in the art and recycled.

Processes herein may be used to thermally crack various hydrocarbon feeds, and may eliminate the refinery altogether while making the crude to chemicals process very flexible in terms of crude. In embodiments herein, crude is progressively separated into at least light and heavy fractions. Depending on the quality of the light and heavy fractions, these are routed to one of three upgrading operations, including a fixed bed hydroconversion unit, a fluidized catalytic conversion unit, or a residue hydrocracking unit that may utilize an ebullated bed reactor. Products from the upgrading operations may be used as feed to a steam cracker.

Processes herein may be used to thermally crack various hydrocarbon feeds, and may eliminate the refinery altogether while making the crude to chemicals process very flexible in terms of crude. In embodiments herein, crude is progressively separated into at least light and heavy fractions. Depending on the quality of the light and heavy fractions, these are routed to one of three upgrading operations, including a fixed bed hydroconversion unit, a fluidized catalytic conversion unit, or a residue hydrocracking unit that may utilize an ebullated bed reactor. Products from the upgrading operations may be used as feed to a steam cracker.

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 high grade coke and fuel grade coke from residual oil comprises: introducing the residual oil and a first paraffinic solvent having a carbon number C.sub.n to a first solvent deasphalting unit to produce a high quality deasphalted oil (HQDAO) fraction and a first asphalt fraction; passing the HQDAO fraction to a delayed coker to produce green coke; passing at least a portion of the first asphalt fraction and a second paraffinic solvent carbon number of C.sub.n+1 to a second solvent deasphalting unit to produce a low quality deasphalted oil (LQDAO) fraction and a second asphalt fraction; and passing the LQDAO fraction to the delayed coker to produce the fuel grade coke.

An integrated process that is operated to create both a higher value pipelineable crude and a higher value carbon fiber product from a lower value common heavy hydrocarbon feedstock where the feedstock is processed in a thermal reactor followed by a solvent deasphalting unit with the liquids being gathered and processed to reduce olefins for pipeline transport and the solids are processed to generate a marketable carbon fiber product with any gases generated throughout the entire process reused in the process or sold.