A feedstock is processed in an FCC unit to produce at least light olefins, FCC naphtha, light cycle oil and heavy cycle oil. Light cycle oil, and in certain embodiments hydrotreated light cycle oil, is subjected to hydrogenation to produce a deeply hydrogenated middle distillate fraction. All or a portion of the deeply hydrogenated middle distillate fraction is used as feed to a petrochemicals production complex to produce light olefins.

Process scheme configurations are disclosed that enable deep hydrogenation of middle distillates. The hydrogenated middle distillates are processed in a petrochemicals production complex for conversion into light olefins and other hydrocarbon products. Feeds to the deep hydrogenation zone include middle distillate range streams from a distillate hydrotreating zone, a vacuum gas oil hydroprocessing zone, and/or a vacuum residue hydrocracking zone. The deep hydrogenation zone operates under conditions effective to reduce aromatic content in a middle distillate range feedstream from a range of about 10-40 wt % or greater, to a hydrogenated distillate range intermediate product having an aromatic content of less than about 5-0.5 wt %.

A multi-stage process for reducing the production of a Product Heavy Marine Fuel Oil from Distressed Fuel Oil Materials (DFOM) involving a pre-treatment process that transforms the DFOM into Feedstock HMFO which is subsequently sent to a Core Process for removing the Environmental Contaminates. The Product Heavy Marine Fuel Oil complies with ISO 8217 for residual marine fuel oils and has 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.

A process for reducing the environmental contaminants in a ISO 8217 compliant Feedstock Heavy Marine Fuel Oil (Feedstock), the process involving: mixing a quantity of the Feedstock with a quantity of Activating Gas mixture to give a feedstock mixture; contacting the feedstock mixture with one or more catalysts to form a Process Mixture from the feedstock mixture; separating the Product Heavy Marine Fuel Oil liquid (Product) components of the Process Mixture from the gaseous components and by-product hydrocarbons of the Process Mixture and, discharging the Product. The Product is compliant with ISO standards for residual marine fuel oils and has a maximum sulfur content between the range of 0.05% wt. to 0.50% wt. The Product can be used as or as a blending stock for compliant, low sulfur or ultralow sulfur heavy marine fuel oil. A device for conducting the process is also disclosed.

A multi-stage process for the production of an ISO8217 compliant Product Heavy Marine Fuel Oil from ISO 8217 compliant Feedstock Heavy Marine Fuel Oil involving a core process under reactive conditions in a Reaction System composed of one or more reaction vessels, wherein one or more of the reaction vessels contains one or more catalysts in the form of a structured catalyst bed and is operated under reactive distillation conditions. The Product Heavy Marine Fuel Oil has 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 for conducting the process is disclosed.

A multi-stage process for the production of an ISO8217 compliant Product Heavy Marine Fuel Oil from ISO 8217 compliant Feedstock Heavy Marine Fuel Oil involving a core process under reactive conditions in a Reaction System composed of one or more reaction vessels, wherein one or more of the reaction vessels contains one or more catalysts in the form of a structured catalyst bed and is operated under reactive distillation conditions. The Product Heavy Marine Fuel Oil has 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 for conducting the process is disclosed.

In accordance with one embodiment of the present disclosure, a heavy oil may be upgraded by a process that may include removing at least a portion of metals from the heavy oil in a hydrodemetalization reaction zone to form a hydrodemetalization reaction effluent, removing at least a portion of metals and at least a portion of nitrogen from the hydrodemetalization reaction effluent in a transition reaction zone to form a transition reaction effluent, removing at least a portion of nitrogen from the transition reaction effluent in a hydrodenitrogenation reaction zone to form a hydrodenitrogenation reaction effluent, and reducing aromatics content in the hydrodenitrogenation reaction effluent in a hydrocracking reaction zone by contacting the hydrodenitrogenation reaction effluent to form an upgraded fuel.

In accordance with one embodiment of the present disclosure, a heavy oil may be upgraded by a process that may include removing at least a portion of metals from the heavy oil in a hydrodemetalization reaction zone to form a hydrodemetalization reaction effluent, removing at least a portion of metals and at least a portion of nitrogen from the hydrodemetalization reaction effluent in a transition reaction zone to form a transition reaction effluent, removing at least a portion of nitrogen from the transition reaction effluent in a hydrodenitrogenation reaction zone to form a hydrodenitrogenation reaction effluent, and reducing aromatics content in the hydrodenitrogenation reaction effluent in a hydrocracking reaction zone by contacting the hydrodenitrogenation reaction effluent to form an upgraded fuel.

A multi-stage process for the production of an ISO 8217 compliant Product Heavy Marine Fuel Oil from ISO 8217 compliant Feedstock Heavy Marine Fuel Oil involving a Reaction System composed of one or more reactor vessels selected from a group reactor wherein said one or more reactor vessels contains one or more reaction sections configured to promote the transformation of the Feedstock Heavy Marine Fuel Oil to the Product Heavy Marine Fuel Oil. The Product Heavy Marine Fuel Oil has a Environmental Contaminate 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 for conducting the process is disclosed that can utilize a modular reactor vessel.

A multi-stage process for the production of an ISO 8217 compliant Product Heavy Marine Fuel Oil from ISO 8217 compliant Feedstock Heavy Marine Fuel Oil involving a Reaction System composed of one or more reactor vessels selected from a group reactor wherein said one or more reactor vessels contains one or more reaction sections configured to promote the transformation of the Feedstock Heavy Marine Fuel Oil to the Product Heavy Marine Fuel Oil. The Product Heavy Marine Fuel Oil has a Environmental Contaminate 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 for conducting the process is disclosed that can utilize a modular reactor vessel.