Processes for treating highly viscous hydrocarbons, such as bitumen from oil sands or petroleum residues, with hydrogen-donor solvents are described. The hydrogen-donor solvent is prepared. A mixture of the hydrocarbon and the hydrogen-donor solvent is heated, and the product is cooled to produce a low viscosity and mildly upgraded hydrocarbon. The hydrogen-donor solvent can be modified to improve its solvent usefulness.

Processes for treating highly viscous hydrocarbons, such as bitumen from oil sands or petroleum residues, with hydrogen-donor solvents are described. The hydrogen-donor solvent is prepared. A mixture of the hydrocarbon and the hydrogen-donor solvent is heated, and the product is cooled to produce a low viscosity and mildly upgraded hydrocarbon. The hydrogen-donor solvent can be modified to improve its solvent usefulness.

Distillate boiling range and/or diesel boiling range compositions are provided that are formed from crude oils with unexpected combinations of high naphthenes to aromatics weight and/or volume ratio and a low sulfur content. This unexpected combination of properties is characteristic of crude oils that can be fractionated to form distillate/diesel boiling range compositions that can be used as fuels/fuel blending products with reduced or minimized processing. The resulting distillate boiling range fractions and/or diesel boiling range fractions can have an unexpected combination of a high naphthenes to aromatics weight and/or volume ratio, a low but substantial aromatics content, and a low sulfur content. By reducing, minimizing, or avoiding the amount of hydroprocessing needed to meet fuel and/or fuel blending product specifications, the fractions derived from the high naphthenes to aromatics ratio and low sulfur crudes can provide fuels and/or fuel blending products having a reduced or minimized carbon intensity.

Distillate boiling range and/or diesel boiling range compositions are provided that are formed from crude oils with unexpected combinations of high naphthenes to aromatics weight and/or volume ratio and a low sulfur content. This unexpected combination of properties is characteristic of crude oils that can be fractionated to form distillate/diesel boiling range compositions that can be used as fuels/fuel blending products with reduced or minimized processing. The resulting distillate boiling range fractions and/or diesel boiling range fractions can have an unexpected combination of a high naphthenes to aromatics weight and/or volume ratio, a low but substantial aromatics content, and a low sulfur content. By reducing, minimizing, or avoiding the amount of hydroprocessing needed to meet fuel and/or fuel blending product specifications, the fractions derived from the high naphthenes to aromatics ratio and low sulfur crudes can provide fuels and/or fuel blending products having a reduced or minimized carbon intensity.

A process for treatment of PFO from a steam cracking zone includes selectively hydrogenating PFO or a portion thereof for conversion of polyaromatics compounds contained in the PFO into aromatic compounds with one benzene ring to produce a selectively hydrogenated stream. The selectively hydrogenated stream is reacted in a fluid catalytic cracking reactor for selective ring opening and dealkylation to produce fluid catalytic cracking including light cycle oil. In addition, a naphtha reformer is integrated, so that light cycle oil and a reformate stream are separated into BTX compounds. Optionally the PFO is separated into a first stream containing C9+ aromatics compounds with one benzene ring, and a second stream containing C10+ aromatic compounds, whereby the first stream containing C9+ aromatics compounds with one benzene ring is passed to the fluid catalytic cracking reactor, and the feed to the selective hydrogenation step comprises all or a portion of the second stream containing C10+ aromatic compounds.

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.

A process for purification a hydrocarbon stream including: (a) Providing a hydrocarbon stream having a diene value of at least 1.0, a bromine number of at least 5 g and containing at least 10 wt % of pyrolysis plastic oil; b) contacting the effluent obtained in step a) with a silica gel, clays, alkaline or alkaline earth metal oxide, iron oxide, ion exchange resins, active carbon, active aluminium oxide, molecular sieves, alkaline oxide and/or porous supports, and/or silica gel, or any mixture thereof; c) performing a first hydrotreating step; d) contacting the effluent obtained in step c) with silica gel, clays, alkaline or alkaline earth metal oxide, iron oxide, ion exchange resins, active carbon, active aluminium oxide, molecular sieves, alkaline oxide and/or porous supports and silica gel, or any mixture thereof; e) performing a second hydrotreating step; and f) recovering a purified hydrocarbon stream.

A process for separating and upgrading a hydrocarbon feed includes passing the hydrocarbon feed to a distillation unit to separate it into at least a naphtha stream and a residue, passing the naphtha stream to a NHT that hydrotreats the naphtha stream to produce a hydrotreated naphtha, passing the hydrotreated naphtha to a NREF that reforms the hydrotreated naphtha to produce a reformate, passing the reformate to an ARC that processes the reformate to produce at least one aromatic product effluent and an aromatic bottoms stream, passing at least a portion of the residue to a residue hydroprocessing unit that hydroprocesses the portion of the residue to produce a hydroprocessed effluent, and passing a portion of the aromatic bottoms stream to the residue hydroprocessing unit to increase the solubility of the asphaltene compounds and reduce sedimentation. Systems for conducting the process are also disclosed.

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.