Co-production of heavy and light base oils

Abstract

A suitable feedstock for forming lubricant base oils is separated into at least a lower boiling portion and a higher boiling portion. The lower boiling portion is combined with a feed suitable for use as a fuels hydrocracking feed. The combined feed is hydrocracked and catalytically dewaxed in order to form fuels and Group II, Group II+, or Group III light neutral basestocks. The higher boiling portion of the feedstock is solvent processed in order to form Group I heavy neutral base oils and/or Group I brightstock base oils. The higher boiling portion of the feedstock can correspond to both a bottoms fraction and one or more additional fractions boiling above a fractionation cut point.

What is claimed is: 
     
         1 . A method for forming fuel and lubricant products, comprising:
 separating a feedstock into at least a first fraction having a T5 boiling point greater than 600° F. (316° C.) and a T95 boiling point of 1150° F. (621° C.) or less and a bottoms fraction;   deasphalting the bottoms fraction to form a deasphalted bottoms fraction and an asphalt product;   extracting the deasphalted bottoms in the presence of an extraction solvent to form a raffinate stream and an extract stream, an aromatics content of the raffinate stream being lower than an aromatics content of the deasphalted bottoms;   dewaxing the raffinate stream in the presence of a dewaxing solvent to form a lubricant base oil product and a wax product;   hydroprocessing a combined feedstock corresponding to the first fraction and a fuels feedstock, at least a portion of the combined feedstock having a boiling point greater than 700° F. (371° C.), the fuels feedstock having a T5 boiling point greater than 350° F. (177° C.) and a T95 boiling point of 1150° F. (621° C.) or less, under first effective hydroprocessing conditions to form a hydroprocessed effluent;   separating the hydroprocessed effluent to form at least a gas phase effluent and a liquid phase effluent;   hydroprocessing at least a portion of the liquid phase effluent in the presence of at least a dewaxing catalyst under second effective hydroprocessing conditions to form a dewaxed effluent, the first effective hydroprocessing conditions and the second effective hydroprocessing conditions being effective for conversion of at least 60% of the portion of the combined feedstock boiling above 700° F. (371° C.) to a portion boiling below 700° F. (371° C.); and   fractionating the dewaxed effluent to form at least a distillate fuel product having a T95 boiling point of 750° F. (399° C.) or less and a lubricant base oil product having a viscosity index of at least 80, a sulfur content of 300 wppm or less, and an aromatics content of 10 wt % or less.   
     
     
         2 . The method of  claim 1 , wherein separating the feedstock comprises:
 separating the feedstock into at least a first fraction having a T5 boiling point greater than 600° F. (316° C.) and a T95 boiling point of 950° F. (510° C.) or less, a second fraction having a T5 boiling point of at least the T95 boiling point of the first fraction, and a bottoms fraction;   
       and wherein extracting the deasphalted bottoms comprises:
 extracting the deasphalted bottoms and the second fraction in the presence of an extraction solvent to form a raffinate stream and an extract stream, an aromatics content of the raffinate stream being lower than an aromatics content of the combined deasphalted bottoms and second fraction. 
 
     
     
         3 . The method of  claim 2 , wherein the first fraction has a T95 boiling point of 850° F. or less. 
     
     
         4 . The method of  claim 2 , wherein, second fraction has a T95 boiling point of 1100° F. or less. 
     
     
         5 . The method of  claim 1 , wherein the first fraction has a T5 boiling point of at least 650° F. 
     
     
         6 . The method of  claim 1 , wherein the first effective hydroprocessing conditions comprise exposing the combined feedstock to a hydrotreating catalyst, a hydrocracking catalyst, or a combination thereof under effective hydrotreating conditions, effective hydrocracking conditions, or a combination thereof. 
     
     
         7 . The method of  claim 6 , wherein the hydrocracking catalyst is USY, zeolite Beta, or a combination thereof. 
     
     
         8 . The method of  claim 1 , wherein the second effective hydroprocessing conditions comprise effective dewaxing conditions. 
     
     
         9 . The method of  claim 1 , wherein the second effective hydroprocessing conditions further comprise exposing the at least a portion of the liquid effluent to a hydrocracking catalyst under second effective hydrocracking conditions. 
     
     
         10 . The method of  claim 1 , wherein the first effective hydroprocessing conditions and the second effective hydroprocessing conditions are effective for conversion of at least 70% of the portion of the combined feedstock boiling above 700° F. (371° C.) to a portion boiling below 700° F. (371° C.). 
     
     
         11 . The method of  claim 1 , wherein separating the hydroprocessed effluent to form at least a gas phase effluent comprises separating the hydroprocessed effluent to form a lower boiling fraction having a T95 boiling point of 400° F. (204° C.) or less. 
     
     
         12 . The method of  claim 1 , wherein separating the hydroprocessed effluent to form at least a liquid phase effluent comprises forming a first liquid phase effluent with a T95 boiling point of 650° F. (343° C.) or less, and a second liquid phase effluent having a T5 boiling point of at least 650° F. (343° C.). 
     
     
         13 . The method of  claim 1 , wherein the liquid phase effluent has a sulfur content of 300 wppm or less. 
     
     
         14 . The method of  claim 1 , further comprising dividing an initial feed into the feedstock and the fuels feedstock. 
     
     
         15 . The method of  claim 1 , further comprising hydrofinishing at least a portion of the dewaxed effluent under effective hydrofinishing conditions. 
     
     
         16 . The method of  claim 1 , wherein separating feedstock comprises:
 separating the feedstock into at least a first fraction having a T5 boiling point greater than 600° F. (316° C.) and a T95 boiling point of 950° F. (510° C.) or less, a second fraction having a T5 boiling point of at least the T95 boiling point of the first fraction, and a bottoms fraction,   the method further comprising:   extracting the second fraction in the presence of an extraction solvent to form a second raffinate stream and a second extract stream, an aromatics content of the second raffinate stream being lower than an aromatics content of the second fraction; and   dewaxing the second raffinate stream in the presence of a dewaxing solvent to form a second lubricant base oil product and a second wax product.   
     
     
         17 . The method of  claim 1 , wherein the first effective hydroprocessing conditions comprise a temperature of 550° F. (288° C.) to 840° F. (449° C.), hydrogen partial pressures of from 250 psig to 5000 psig (1.8 MPag to 34.6 MPag), and a hydrogen treat gas rate of from 35.6 m 3 /m 3  to 1781 m 3 /m 3  (200 SCF/B to 10,000 SCF/B), and wherein the second effective hydroprocessing conditions comprise a temperature of from 200 to 450° C., a hydrogen partial pressure of from 1.8 MPag to 34.6 MPag (250 psig to 5000 psig), and a hydrogen treat gas rate of from 35.6 m 3 /m 3  (200 SCF/B) to 1781 m 3 /m 3  (10,000 scf/B).