The invention is an integrated process for treating residual oil of a hydrocarbon feedstock. The oil is first subjected to solvent deasphalting then gas phase oxidative desulfurization. Additional, optional steps including hydrodesulfurization, and hydrocracking, may also be incorporated into the integrated process.

Methods are provided to prepare a low sulfur fuel from hydrocarbon sources, such as light tight oil and high sulfur fuel oil, often less desired by conventional refiners, who split crude into a wide range of differing products and may prefer presence of wide ranges (C3 or C5 to C20 or higher) of hydrocarbons. These fuels can be produced by separating feeds into untreated and treated streams, and then recombining them. Such fuels can also be formulated by combinations of light, middle and heavy range constituents in a selected manner as claimed. Not only low in sulfur, the fuels of this invention are also low in nitrogen and essentially metals free. Fuel use applications include on-board large marine transport vessels but also on-shore for large land based combustion gas turbines, boilers, fired heaters and transport vehicles and trains.

The invention relates to a process for converting a heavy hydrocarbon feedstock containing a fraction of at least 50% with a boiling point of at least 300 C., and containing sulfur, Conradson carbon, metals, and nitrogen, comprising at least two successive hydroconversion steps, which may be separated by an intermediate separation step, and at least one step of deasphalting a heavy fraction of the effluent resulting from the hydroconversion, with recycling at least one portion of the deasphalted oil (DAO) during the hydroconversion, downstream of the first hydroconversion step. The DAO is either recycled at the outlet thereof from the deasphalter, or after having undergone a fractionation step that produces a heavy fraction of the DAO that then constitutes the portion of the DAO that is recycled. This process makes it possible to simultaneously improve the degree of conversion and the stability of the liquid effluents.

Systems and methods are provided for upgrading catalytic slurry oil. The upgrading can be performed by deasphalting the catalytic slurry oil to form a deasphalted oil and a residual or rock fraction. The deasphalted oil can then be hydroprocessed to form an upgraded effluent that includes fuels boiling range products.

Systems and methods are provided for improving the processing of heavy or challenged feeds in a refinery based on integrated use of deasphalting, coking, and hydroprocessing. An optional fluid catalytic cracking unit can be included in the integrated system to allow for further improvements. The improved processing can be facilitated based on a process configuration where the vacuum resid fractions and/or other difficult fractions are deasphalted to generate a deasphalted oil and a deasphalter residue or rock fraction. The deasphalted oil can be passed into a hydroprocessing unit for further processing. The rock fraction can be used as the feed to a coking unit. Although deasphalter residue or rock is typically a feed with a high content of micro carbon residue, a high lift deasphalting process can allow a portion of the micro carbon residue in the initial feed to remain with the deasphalted oil. The portion of micro carbon residue that remains in the deasphalted oil can then be upgraded during hydroprocessing and/or during subsequent processing of the feed. By reducing the amount of micro carbon residue passed into a coker for a given initial feed source, the overall capacity for a reaction system to handle heavy feeds can be increased relative to the rate of coke production from the reaction system.

The invention relates to processes for producing anode grade coke from whole crude oil. The invention is accomplished by first deasphalting a feedstock, followed by processing resulting DAO and asphalt fractions. The DAO fraction is hydrotreated or hydrocracked, resulting in removal of sulfur and hydrocarbons, which boil at temperatures over 370 C., and gasifying the asphalt portion in one embodiment. This embodiment includes subjecting hydrotreated and/or unconverted DAO fractions to delayed coking. In an alternate embodiment, rather than gasifying the asphalt portion, it is subjected to delayed coking in a separate reaction chamber. Any coke produced via delayed coking can be gasified.

Fuels and/or fuel blending components can be formed from hydroprocessing of high lift deasphalted oil. The high lift deasphalting can correspond to solvent deasphalting to produce a yield of deasphalted oil of at least 50 wt %, or at least 65 wt %, or at least 75 wt %. The resulting fuels and/or fuel blending components formed by hydroprocessing of the deasphalted oil can have unexpectedly high naphthene content and/or density. Additionally or alternately, deasphalted oil generated from high lift deasphalting represents a disadvantaged feed that can be converted into a fuel and/or fuel blending components with unexpected compositions. Additionally or alternately, the resulting fuels and/or fuel blending components can have unexpectedly beneficial cold flow properties, such as cloud point, pour point, and/or freeze point.

The invention is an integrated process for treating residual oil of a hydrocarbon feedstock. The oil is first subjected to solvent deasphalting then gas phase oxidative desulfurization. Additional, optional steps including hydrodesulfurization, and hydrocracking, may also be incorporated into the integrated process.

Compositions are provided for lubricant base stocks produced from feeds such as vacuum resid or other 510 C.+ feeds. A feed can be deasphalted and then catalytically and/or solvent processed to form lubricant base stocks, including bright stocks that are resistant to haze formation.

Deasphalter rock from high lift deasphalting can be combined with a flux to form a fuel oil blending component. The high lift deasphalting can correspond to solvent deasphalting to produce a yield of deasphalted oil of at least 50 wt %, or at least 65 wt %, or at least 75 wt %. The feed used for the solvent deasphalting can be a resid-containing feed. The resulting fuel oil blendstock made by fluxing of high lift deasphalter rock can have unexpectedly beneficial properties when used as a blendstock.