A process for upgrading heavy oil is provided, which integrates thermal cracking, hydrogenolysis, and catalytic aquathermolysis. A catalytic hydrogen-aquathermolysis reactor receives a heavy oil feed, water and hydrogen. In addition catalytic materials and a viscosity reducing agent are introduced. The catalytic hydrogen-aquathermolysis reactor is operated at conditions effective to produce an upgraded heavy oil product.

A process for upgrading heavy oil is provided, which integrates thermal cracking, hydrogenolysis, and catalytic aquathermolysis. A catalytic hydrogen-aquathermolysis reactor receives a heavy oil feed, water and hydrogen. In addition catalytic materials and a viscosity reducing agent are introduced. The catalytic hydrogen-aquathermolysis reactor is operated at conditions effective to produce an upgraded heavy oil product.

A hydrocracking process is disclosed. The hydrocracking process comprises hydrocracking a hydrocarbon feed stream in a hydrocracking reactor in the presence of a hydrogen stream and a hydrocracking catalyst to produce a hydrocracked effluent stream. The hydrocracked effluent stream is separated in a separator to provide a vapor hydrocracked stream and a liquid hydrocracked stream. The liquid hydrocracked stream is fractionated to provide a naphtha stream, a kerosene stream having a T90 temperature of about 204° C. (399° F.) to about 238° C. (460° F.), a diesel stream having a T90 temperature of about 360° C. (680° F.) to about 383° C. (721° F.) and an unconverted oil stream. The kerosene stream, the unconverted oil stream, and a portion of the diesel stream is recycled to the hydrocracking reactor for hydrocracking.

A hydrocracking process is disclosed. The hydrocracking process comprises hydrocracking a hydrocarbon feed stream in a hydrocracking reactor in the presence of a hydrogen stream and a hydrocracking catalyst to produce a hydrocracked effluent stream. The hydrocracked effluent stream is separated in a separator to provide a vapor hydrocracked stream and a liquid hydrocracked stream. The liquid hydrocracked stream is fractionated to provide a naphtha stream, a kerosene stream having a T90 temperature of about 204° C. (399° F.) to about 238° C. (460° F.), a diesel stream having a T90 temperature of about 360° C. (680° F.) to about 383° C. (721° F.) and an unconverted oil stream. The kerosene stream, the unconverted oil stream, and a portion of the diesel stream is recycled to the hydrocracking reactor for hydrocracking.

In accordance with one or more embodiments of the present disclosure, a process for treating a hydrocarbon feedstream having nitrogen-containing compounds and polynuclear aromatic compounds includes contacting the hydrocarbon feedstream with an adsorbent material; introducing the adsorbent-treated hydrocarbon feedstream to a hydrocracking reaction unit to produce a hydrocracked effluent stream; introducing a naphtha stream to a catalytic reforming unit to produce a reformate stream; introducing the reformate stream to an aromatic recovery complex to produce a light reformate stream, a BTX stream, and an aromatic bottoms stream; and introducing the aromatic bottoms stream to the used adsorbent to release at least a portion of the nitrogen-containing compounds and polynuclear compounds.

An upgraded crude composition is provided, along with systems and methods for making such a composition. The upgraded crude composition can include an unexpectedly high percentage of vacuum gas oil boiling range components while having a reduce or minimized amount of components boiling above 593° C. (1100° F.). In some aspects, based in part on the hydroprocessing used to form the upgraded crude composition, the composition can include unexpectedly high contents of nitrogen. Still other unexpected features of the composition can include, but are not limited to, an unexpectedly high nitrogen content in the naphtha fraction; and an unexpected vacuum gas oil fraction including an unexpectedly high content of polynuclear aromatics, an unexpectedly high content of waxy, paraffinic compounds, and/or an unexpectedly high content of n-pentane asphaltenes.

An upgraded crude composition is provided, along with systems and methods for making such a composition. The upgraded crude composition can include an unexpectedly high percentage of vacuum gas oil boiling range components while having a reduce or minimized amount of components boiling above 593° C. (1100° F.). In some aspects, based in part on the hydroprocessing used to form the upgraded crude composition, the composition can include unexpectedly high contents of nitrogen. Still other unexpected features of the composition can include, but are not limited to, an unexpectedly high nitrogen content in the naphtha fraction; and an unexpected vacuum gas oil fraction including an unexpectedly high content of polynuclear aromatics, an unexpectedly high content of waxy, paraffinic compounds, and/or an unexpectedly high content of n-pentane asphaltenes.

Integrated processes and systems for the production of distillate hydrocarbons and coke. The process may include feeding a hydrocarbon feedstock, comprising a residuum hydrocarbon fraction, to a residue hydrocracking reactor system to convert hydrocarbons therein, producing a hydrocracked effluent. The hydrocracked effluent may then be fed to a separation system, separating the hydrocracked effluent into one or more distillate hydrocarbon fractions and a vacuum residue fraction. The vacuum residue fraction may be fed to a coker system, converting the vacuum residue fraction into a coke product and a coker vapor effluent, recovering the coke product, and feeding the coker vapor effluent to the separation system. The one or more distillate hydrocarbon fractions are hydroprocessed to produce a hydroprocessed effluent, and the hydroprocessed effluent is separated into product distillate hydrocarbon fractions.

Integrated processes and systems for the production of distillate hydrocarbons and coke. The process may include feeding a hydrocarbon feedstock, comprising a residuum hydrocarbon fraction, to a residue hydrocracking reactor system to convert hydrocarbons therein, producing a hydrocracked effluent. The hydrocracked effluent may then be fed to a separation system, separating the hydrocracked effluent into one or more distillate hydrocarbon fractions and a vacuum residue fraction. The vacuum residue fraction may be fed to a coker system, converting the vacuum residue fraction into a coke product and a coker vapor effluent, recovering the coke product, and feeding the coker vapor effluent to the separation system. The one or more distillate hydrocarbon fractions are hydroprocessed to produce a hydroprocessed effluent, and the hydroprocessed effluent is separated into product distillate hydrocarbon fractions.

Methods of refining a whole crude oil stream. The methods involve first processing the crude either through a hydrotreating reactor comprising a dewaxing reactor bed or a flash evaporation separator. The treated streams are then further processed through a demetalization reactor bed, a hydroprocessing reactor bed, or both. The stream can then be still further processed via additional hydrotreating, distillation, or both.