The present invention relates to a method for oxidizing asphalt which comprises dispersing an oxygen containing gas throughout an asphalt flux in an oxidation zone while the asphalt flux is maintained at a temperature which is within the range of about 400 F. to 550 F., wherein the oxygen containing gas is introduced into the oxidation zone through a recycle loop. The recycle loop pumps asphalt flux from the oxidation zone and reintroduces the asphalt flux into the oxidation zone as oxygen enhanced asphalt flux. The recycle loop will typically include a pump which pulls the asphalt flux from the oxidation zone and which pumps the oxygen enhanced asphalt flux into the oxidation zone, and wherein the oxygen containing gas is injected into the recycle loop at a point before the asphalt flux enters into the pump.

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.

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.

Pitch particles may be produced by a grinding process, in which pitch fines may be recovered and recycled to a grinding apparatus as a pitch melt. Such methods may comprise: providing a petroleum pitch having a first softening temperature; grinding the petroleum pitch in a grinding apparatus below the first softening temperature to produce a plurality of pitch particles and a plurality of pitch fines; separating the pitch particles from the pitch fines; heating the pitch fines at a temperature above the first softening temperature to produce a pitch melt; and combining the pitch melt with the petroleum pitch in the grinding apparatus. The pitch melt hardens in the grinding apparatus and is reground. The pitch particles may be further stabilized by heating at a treatment temperature below the first softening temperature in an environment comprising about 1 mol % to about 20 mol % oxygen to form stabilized pitch particles.

Pitch particles may be produced by a grinding process, in which pitch fines may be recovered and recycled to a grinding apparatus as a pitch melt. Such methods may comprise: providing a petroleum pitch having a first softening temperature; grinding the petroleum pitch in a grinding apparatus below the first softening temperature to produce a plurality of pitch particles and a plurality of pitch fines; separating the pitch particles from the pitch fines; heating the pitch fines at a temperature above the first softening temperature to produce a pitch melt; and combining the pitch melt with the petroleum pitch in the grinding apparatus. The pitch melt hardens in the grinding apparatus and is reground. The pitch particles may be further stabilized by heating at a treatment temperature below the first softening temperature in an environment comprising about 1 mol % to about 20 mol % oxygen to form stabilized pitch particles.