Heavy feed upgrading based on solvent deasphalting followed by slurry hydroprocessing of asphalt from solvent deasphalting (fcb-0009)

Abstract

A process for upgrading a feedstream, said process comprising: (a) solvent deasphalting, under solvent deasphalting conditions, said feedstream to obtain a first product stream comprising deasphalted oil and a second product stream comprising asphalt product; (b) slurry hydroprocessing said asphalt product in a slurry hydroprocessing unit under slurry hydroprocessing conditions to obtain a hydroprocessed product; and (c) separating an upgraded oil from the hydroprocessed product and unconverted asphaltene bottoms.

What is claimed is:  
     
         1 . A process for upgrading a feedstream, said process comprising: 
 (a) solvent deasphalting, under solvent deasphalting conditions, said feedstream to obtain a first product stream comprising deasphalted oil and a second product stream comprising asphalt product; (b) slurry hydroprocessing said asphalt product in a slurry hydroprocessing unit under slurry hydroprocessing conditions to obtain a hydroprocessed product; and (c) separating an upgraded oil from the hydroprocessed product and unconverted asphaltene bottoms.    
     
     
         2 . The process of  claim 1  further comprising combining said recovered upgraded oil of said step (c) with said deasphalted oil of step (a) to obtain a finished upgraded crude.  
     
     
         3 . The process of  claim 1  wherein said hydroprocessed products are further solvent deasphalted to obtain solvent deasphalted oil.  
     
     
         4 . The process of  claim 3  wherein said solvent deasphalted oil obtained from said hydroprocessed product is combined with said deasphalted oil of said step (a).  
     
     
         5 . The process of  claim 1  wherein said hydroprocessed product is distilled to recover 1025−° F. liquid and said 1025−° F. liquid is then combined with said solvent deasphalted oil of step (a).  
     
     
         6 . The process of  claim 1  wherein said feed stream is selected from the group consisting of virgin crudes or petroleum distillation residues having an API gravity of ≦10 to 15° with a viscosity of ≧60 centistokes at 60° C., and mixtures thereof.  
     
     
         7 . The process of  claim 1  wherein said solvent deasphalting is conducted utilizing as a solvent a C 3 , C 4 , C 5  paraffin, natural gas condensate, or combinations thereof.  
     
     
         8 . The process of  claim 1  wherein said solvent deasphalting is conducted at about 275 to about 310° F.  
     
     
         9 . The process of  claim 1  wherein said slurry hydroprocessing is conducted at temperatures of about 725° F. to about 850° F. and pressures from about 800 to about 2500 psig.  
     
     
         10 . The process of  claim 1  wherein said slurry hydroprocessing step (b) is conducted utilizing a catalyst, catalyst precursor, or combination of a catalyst and catalyst precursor selected from the group consisting of vanadyl oxylate, phosphomolybdic acid, calcined asphalt from solvent deasphalting, and mixtures thereof.  
     
     
         11 . The process of  claim 10  wherein said catalyst, catalyst precursor or combination thereof is sulfided in-situ or ex-situ.  
     
     
         12 . The process of  claim 1  wherein said hydroprocessing step utilizes the residue from calcining of asphalt from solvent deasphalting as catalyst.  
     
     
         13 . The process of  claim 3  wherein said solvent deasphalting is accomplished by recycling said hydroprocessed products to said step (a).  
     
     
         14 . A fully integrated process for upgrading a feedstream comprising the steps of (a) solvent deasphalting, under solvent deasphalting conditions, said feedstream to obtain a first product stream comprising deasphalted oil and a second product stream comprising asphalt product; (b) slurry hydroprocessing said asphalt product in a slurry hydroprocessing unit under slurry hydroprocessing conditions to obtain a hydroprocessed product; and (c) recycling said hydroprocessed product of said step (b) to said step (a).  
     
     
         15 . The process of  claim 10  wherein the concentration of molybdenum catalyst on feed is 10 to 800 wppm, calculated as the metal.  
     
     
         16 . The process of  claim 1  wherein the amount of toluene insolubles produced by said process is no more than 0.5 wt % based on said asphalt product hydroprocessed.