The present disclosure generally relates to upgrading difficult to process heavy-oil. In particular, the disclosure relates to upgrading heavy oil and other high carbon content materials by using an integrated thermal-process (ITP) that utilizes anti-coking management and toluene insoluble organic residues (TIOR) management to directly incorporate lighter hydrocarbons into high molecular weight, low hydrogen content hydrocarbons such as thermally processed heavy oil products. This process can be integrated with other thermal processing schemes, such as cokers and visbreakers, to improve the conversion and yields from these integrated processes.

The present invention is based on the use of a two-step hydrocracking process comprising a step of hydrogenation placed upstream of the second hydrocracking step, the hydrogenation step treating the unconverted liquid fraction separated in the distillation step in the presence of a specific hydrogenation catalyst. Furthermore, the hydrogenation step and second hydrocracking step are carried out under specific operating conditions and in particular under very specific temperature conditions.

The present invention is based on the use of a two-step hydrocracking process comprising a step of hydrogenation placed upstream of the second hydrocracking step, the hydrogenation step treating the unconverted liquid fraction separated in the distillation step in the presence of a specific hydrogenation catalyst. Furthermore, the hydrogenation step and second hydrocracking step are carried out under specific operating conditions and in particular under very specific temperature conditions.

The invention relates to the implementation of a multi-stage hydrocracking process comprising a hydrogenation stage located downstream of the second hydrocracking stage, said hydrogenation stage treating the effluent produced in the second hydrocracking stage, in the presence of a specific hydrogenation catalyst. In addition, the hydrogenation and second hydrocracking stages are implemented under specific operating conditions and particularly under very specific temperature conditions.

The invention relates to the implementation of a multi-stage hydrocracking process comprising a hydrogenation stage located downstream of the second hydrocracking stage, said hydrogenation stage treating the effluent produced in the second hydrocracking stage, in the presence of a specific hydrogenation catalyst. In addition, the hydrogenation and second hydrocracking stages are implemented under specific operating conditions and particularly under very specific temperature conditions.

Systems and methods are provided for performing the initial heating phase for a thick wall reactor, such as a hydroprocessing reactor, by using heat tracing to heat the exterior walls of the reactor. Instead of attempting to initially heat the reactor by passing a low pressure heat transfer gas through the interior of the reactor, external heater(s) placed under the reactor insulation can be used to heat the exterior of the reactor. An example of a suitable external heater is a heat tracing blanket, where heat is provided by passing steam through pipes in contact with the external surface or by electrical heaters in contact with the external surface. This can allow for more rapid heating of the reactor, so that a target temperature can be achieved in a time of 5.0 hours or less.

Systems and methods are provided for performing the initial heating phase for a thick wall reactor, such as a hydroprocessing reactor, by using heat tracing to heat the exterior walls of the reactor. Instead of attempting to initially heat the reactor by passing a low pressure heat transfer gas through the interior of the reactor, external heater(s) placed under the reactor insulation can be used to heat the exterior of the reactor. An example of a suitable external heater is a heat tracing blanket, where heat is provided by passing steam through pipes in contact with the external surface or by electrical heaters in contact with the external surface. This can allow for more rapid heating of the reactor, so that a target temperature can be achieved in a time of 5.0 hours or less.

Systems and methods to provide low carbon intensity (CI) transportation fuels through one or more targeted reductions of carbon emissions based upon an analysis of carbon emissions associated with a combination of various options for feedstock procurement, feedstock refining, processing, or transformation, and fuel product distribution pathways to end users. Such options are selected to maintain the total CI (carbon emissions per unit energy) of the transportation fuel below a pre-selected threshold that defines an upper limit of CI for the transportation fuel.

Systems and methods to provide low carbon intensity (CI) ethanol through one or more targeted reductions of carbon emissions based upon an analysis of carbon emissions associated with a combination of various options for feedstock procurement, feedstock refining, processing, or transformation, and ethanol distribution pathways to end users. Such options are selected to maintain the total CI (carbon emissions per unit energy) of the ethanol below a pre-selected threshold that defines an upper limit of CI for the ethanol.

Systems and methods to provide low carbon intensity (CI) hydrogen through one or more targeted reductions of carbon emissions based upon an analysis of carbon emissions associated with a combination of various options for feedstock procurement, feedstock refining, processing, or transformation, and hydrogen distribution pathways to end users. Such options are selected to maintain the total CI (carbon emissions per unit energy) of the hydrogen below a pre-selected threshold that defines an upper limit of CI for the hydrogen.