Integrated hydrocracking process to produce light olefins, aromatics, and lubricating base oils from crude oil

Abstract

A method of producing one or more olefins and one or more lubricating base oils is disclosed. The method includes hydrocracking hydrocarbons of a hydrocarbon feed stream that include vacuum gasoil to produce a stream that includes hydrocracked hydrocarbons. The method further includes fractionating the stream that includes hydrocracked hydrocarbons to form intermediate streams. The method further includes steam cracking one or more of the intermediate streams to produce at least one olefin and processing one or more of the intermediate streams to produce at least one lubricating base oil.

1 . A method of producing olefins and/or aromatics and lubricating base oils, the method comprising:
 hydrocracking a vacuum residue stream to produce a first stream comprising gasoil and a second stream comprising heavy unconverted oil;   de-asphalting the second stream to produce a third stream comprising de-asphalted oil;   processing at least a first portion of the third stream to produce one or more lubricating base oils, wherein the processing of the first portion of the third stream comprises subjecting, in a partial conversion hydrocracking unit, the first portion of the third stream to partial conversion hydrocracking conditions; and   processing at least a portion of the first stream to produce one or more olefins and/or one or more aromatics, wherein the processing of the portion of the first stream comprises subjecting, in a maximum conversion hydrocracking unit, the portion of the first stream to maximum conversion hydrocracking conditions.   
     
     
         2 . The method of  claim 1 , further comprising:
 flowing a fourth stream comprising a heavy fraction from the maximum conversion hydrocracking unit to the de-asphalting unit.   
     
     
         3 . The method of  claim 2 , wherein the heavy fraction of the fourth stream comprises primarily polyaromatic hydrocarbons and other hydrocarbons with a boiling range of above 350° C., collectively. 
     
     
         4 . The method of  claim 1 , wherein the de-asphalting comprises contacting the second stream with one or more of propane, butane, and pentane. 
     
     
         5 . The method of any of  claims 1  to  2 , wherein the de-asphalted oil comprises primarily hydrocarbons with boiling points above 400° C. 
     
     
         6 . The method of  claim 1 , wherein the partial conversion hydrocracking conditions comprise a reaction temperature of 300 to 450° C. and a reaction pressure of 80 to 200 bar. 
     
     
         7 . The method of  claim 1 , wherein the partial conversion hydrocracking conditions comprise a weight hourly space velocity of 0.05 to 10 hr −1 . 
     
     
         8 . The method of  claim 1 , wherein the maximum conversion hydrocracking conditions comprise a reaction temperature of 300 to 450° C. and a reaction pressure of 80 to 200 bar. 
     
     
         9 . The method of  claim 1 , wherein the maximum conversion hydrocracking conditions comprise a weight hourly space velocity of 0.05 to 10 hr −1 . 
     
     
         10 . The method of  claim 1 , wherein the subjecting of the first portion of the third stream to partial conversion hydrocracking conditions produces a seventh stream comprising naphtha, an eighth stream comprising diesel, and a ninth stream comprising white unconverted oil. 
     
     
         11 . The method of  claim 10 , wherein the processing of the first portion of the third stream further comprises:
 processing the ninth stream under hydroprocessing conditions sufficient to produce the one or more lubricating oils.   
     
     
         12 . The method of  claim 11 , wherein the hydroprocessing conditions include a weight ratio of hydrogen to feed in a range of 0.1% to 15%. 
     
     
         13 . The method of  claim 11 , wherein the hydroprocessing conditions include a hydroprocessing temperature of 200 to 450° C. and a hydroprocessing pressure of 20 to 200 bar. 
     
     
         14 . The method of  claim 11 , wherein the step of subjecting the at least a portion of the first stream to maximum conversion hydrocracking conditions is adapted to produce a fifth stream comprising naphtha and a sixth stream comprising diesel. 
     
     
         15 . The method of  claim 14 , further comprising:
 subjecting, in a maximum conversion hydrocracking unit, a second portion of the third stream to the maximum conversion hydrocracking conditions to produce additional naphtha in the fifth stream and additional diesel in the sixth stream.   
     
     
         16 . The method of  claim 15 , further comprising steam-cracking the naphtha of the fifth stream to produce the light olefins and/or BTX. 
     
     
         17 . The method of  claim 1 , wherein the de-asphalting step further produces a tenth stream comprising pitch. 
     
     
         18 . The method of  claim 3 , wherein the de-asphalting step further produces a tenth stream comprising pitch. 
     
     
         19 . The method of  claim 4 , wherein the de-asphalting step further produces a tenth stream comprising pitch. 
     
     
         20 . The method of  claim 5 , wherein the de-asphalting step further produces a tenth stream comprising pitch.