A multi-stage process for transforming a high sulfur ISO 8217 compliant Feedstock Heavy Marine Fuel Oil involving a core desulfurizing process that produces a Product Heavy Marine Fuel Oil that can be used as a feedstock for subsequent refinery process such as anode grade coking, needle coking and fluid catalytic cracking. The Product Heavy Marine Fuel Oil exhibits multiple properties desirable as a feedstock for those processes including a sulfur level has a maximum sulfur content (ISO 14596 or ISO 8754) between the range of 0.05 mass % to 1.0 mass. A process plant for conducting the process is also disclosed.

The present invention deals with activation and start-up procedures of catalysts for the deep HDS of middle distillates for producing ultra low sulfur diesel (ULSD), consisting of two in situ activation stages: at stage 1, TGA is applied, and at stage 2, DMDS is used; kerosene is the transport means at these stages, which are carried out under given temperature and pressure conditions, and feedstock and hydrogen flows at established times. After the activation of the catalyst in situ, the stabilization stage takes place under selected temperature and pressure conditions, feedstock and hydrogen flow at established times, with which the stabilization of the highly dispersed metallic sulfides is achieved and, in this way, the activity of the catalysts removing contaminants for the production of ULSD is increased.

According to at least one aspect of the present disclosure, a process for processing a crude oil with an API between 30 and 35 degrees includes contacting the crude oil with one or more hydroprocessing catalysts to produce a hydroprocessed effluent. The hydroprocessed effluent is passed to an HS-FCC unit, where the hydroprocessed effluent is contacted with a cracking catalyst composition comprising nano-ZSM-5 zeolite and an ultrastable Y-type zeolite (USY zeolite) to form a cracked effluent comprising at least one product. The HS-FCC catalyst composition further comprises nano-ZSM-5 zeolite that has an average particle size of from 0.01 micrometers (μm) to 0.2 μm, USY zeolite impregnated with lanthanum, an alumina binder, colloidal silica, and a matrix material comprising Kaolin clay. The cracked effluent comprises at least olefins, aromatic compounds, or both.

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

For the shipping industry, these fuels provide solutions to long outstanding technical problems that heretofore hindered supply of low sulfur marine fuels in quantities needed to meet worldwide sulfur reduction goals. Marine shipping use of high sulfur bunker oils is reported as largest source of worldwide transportation SOx emissions. When ships on the open seas burn cheap low grade heavy bunker oils high in sulfur, nitrogen and metals, the SOx, NOx, and metal oxides go to the environment. This invention converts essentially all of each barrel of crude feed to a single ultraclean fuel versus conventional refining where crude feed is cut into many pieces, and each piece is sent down a separate market path meeting various different product specifications. When in port, ships can use these fuels to generate and sell electricity to land based electrical grids to offset fuel cost in an environment-friendly manner.

For the shipping industry, these fuels provide solutions to long outstanding technical problems that heretofore hindered supply of low sulfur marine fuels in quantities needed to meet worldwide sulfur reduction goals. When ships on the open seas burn cheap low grade heavy bunker oils high in sulfur, nitrogen and metals, the SOx, NOx, and metal oxides go to the environment. This invention converts essentially all of each barrel of crude feed to a single ultraclean fuel versus conventional refining where crude feed is cut into many pieces, and each piece is sent down a separate market path meeting various different product specifications. When in port, ships can generate and sell electricity to land based electrical grids to offset fuel cost in an environment-friendly manner.

For the shipping industry, these fuels provide solutions to long outstanding technical problems that heretofore hindered supply of low sulfur marine fuels in quantities needed to meet worldwide sulfur reduction goals. When ships on the open seas burn cheap low grade heavy bunker oils high in sulfur, nitrogen and metals, the SOx, NOx, and metal oxides go to the environment. This invention converts essentially all of each barrel of crude feed to a single ultraclean fuel versus conventional refining where crude feed is cut into many pieces, and each piece is sent down a separate market path meeting various different product specifications. When in port, ships can generate and sell electricity to land based electrical grids to offset fuel cost in an environment-friendly manner.

A process for steam cracking a whole crude including a volatilization step performed to maintain a relatively large hydrocarbon droplet size. The process may include contacting a whole crude with steam to volatilize a portion of the hydrocarbons, wherein the contacting of the hydrocarbon feedstock and steam is conducted at an initial relative velocity of less than 30 m/s, for example. The resulting vapor phase, including volatilized hydrocarbons and steam may then be separated from a liquid phase comprising unvaporized hydrocarbons. The hydrocarbons in the vapor phase may then be forwarded to a steam pyrolysis reactor for steam cracking of the hydrocarbons in the vapor phase.

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.

In accordance with one or more embodiments of the present disclosure, process for reforming a diesel feedstock to convert diesel to a gasoline blending component includes hydrodesulfurizing and hydrodenitrogenizing the diesel feedstock to reduce a sulfur content of the diesel feedstock and a nitrogen content of the diesel feedstock; hydrocracking the hydrodesulfurized and hydrodenitrogenized diesel feedstock over a metal-containing diesel hydrocracking catalyst comprising at least one zeolite to produce an isomerate fraction; and separating the isomerate fraction into a first stream enriched in n-paraffins and a second stream enriched in iso-paraffins and naphthenes.