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.

A processing facility is provided. The processing facility includes an asphaltenes and metals (AM) removal system configured to process a feed stream to produce a power generation stream, a hydroprocessing feed stream, and an asphaltenes stream. A power generation system is fed by the power generation feed stream. A hydroprocessing system is configured to process the hydroprocessing feed stream to form a gas stream and a liquid stream. A hydrogen production system is configured to produce hydrogen, carbon monoxide and carbon dioxide from the gas feed stream. A carbon dioxide conversion system is configured to produce synthetic hydrocarbons from the carbon dioxide, and a cracking system is configured to process the liquid feed stream.

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.

A system for processing a stream including fuel oil includes an atmospheric flash column for receiving the stream as feedstock and separate the stream into an atmospheric flash distillate stream and an atmospheric flash residue stream. The system includes a vacuum flash column for receiving the atmospheric flash residue stream and separating the atmospheric flash residue stream into a vacuum flash distillate stream, a vacuum flash residue stream, and a vacuum gas oil stream. The system includes a first hydrocracking unit for receiving and processing at least a portion of the vacuum flash residue stream to produce an intermediate stream and a slurry. The system includes a second hydrocracking unit for receiving and processing the vacuum gas oil stream and the intermediate stream to produce a naphtha product and a light ends product. The system includes a pelletization unit for receiving and processing the slurry to produce a pelletized product.

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.

Methods and systems for producing anode grade coke are disclosed, which allow anode grade coke to be produced from crude oil having a high sulfur content. A fraction of the resid is hydrotreated while another fraction of the resid is treated in a solvent deasphalting unit. A synthetic stream is provided by blending hydrotreated resid with one or more streams from the deasphalting unit. The synthetic stream is fed to an anodic coker unit.

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.