Fixed bed hydroprocessing of deasphalter rock

Abstract

Systems and methods are provided for fixed bed hydroprocessing of deasphalter rock. Instead of attempting to process vacuum resid in a fixed bed processing unit, vacuum resid is deasphalted to form a deasphalted oil and deasphalter residue or rock. The rock can then be hydroprocessed in a fixed bed reaction zone, optionally after combining the rock with an aromatic co-feed and/or a hydroprocessing solvent. This can allow for improved conversion of the deasphalter rock and/or improved combined conversion of the deasphalter rock and deasphalted oil.

What is claimed is: 
     
         1 . A method for fixed bed processing of deasphalter rock, comprising:
 exposing a feedstock comprising deasphalter rock and a co-feed comprising a catalytic slurry oil, a lubes extract, a heavy coker gas oil, a vacuum gas oil derived from a heavy oil, or a combination thereof, to a fixed bed of hydroprocessing catalyst under hydroprocessing conditions effective for conversion of at least 40 wt % of the deasphalter rock relative to a conversion temperature of 1050° F. (566° C.) to form a hydroprocessed effluent, the feedstock comprising at least about 20 wt % of the co-feed and at least about 10 wt % of the deasphalter rock.   
     
     
         2 . The method of  claim 1 , wherein the feedstock comprises at least about 30 wt % of the deasphalter rock. 
     
     
         3 . The method of  claim 1 , further comprising performing solvent deasphalting on a resid feedstock to form at least the deasphalter rock and a deasphalted oil fraction, the resid feedstock having a T10 distillation point of at least about 650° F. (˜343° C.), the deasphalter rock comprising at least about 10 wt % of the resid feedstock. 
     
     
         4 . The method of  claim 1 , wherein the feedstock comprises at least about 20 wt % of the catalytic slurry oil. 
     
     
         5 . The method of  claim 1 , wherein the feedstock comprises at least about 30 wt % of the co-feed. 
     
     
         6 . The method of  claim 1 , wherein the feedstock further comprises an aromatic solvent, the aromatic comprising at least 50 wt % of aromatic compounds relative to a weight of the aromatic solvent, the aromatic solvent having a boiling range from about 100° C. to about 500° C. 
     
     
         7 . The method of  claim 6 , wherein the aromatic solvent has a final boiling point or a T95 boiling point of about 300° C. or less, or wherein the aromatic solvent has a final boiling point or a T95 boiling point of about 350° C. or less and the feedstock comprises about 40 wt % or less of the aromatic solvent, or wherein the aromatic solvent has a final boiling point or a T95 boiling point of about 400° C. or less and the feedstock comprises about 30 wt % or less of the aromatic solvent. 
     
     
         8 . The method of  claim 1 , further comprising fractionating at least a portion of the hydroprocessed effluent to form a hydroprocessed bottoms fraction and at least one of a naphtha boiling range fraction and a diesel boiling range fraction; deasphalting at least a portion of the hydroprocessed bottoms fraction to form a hydroprocessed deasphalted oil; and processing at least a portion of the hydroprocessed deasphalted oil under fluid catalytic cracking conditions. 
     
     
         9 . The method of  claim 8 , wherein processing the at least a portion of the hydroprocessed deasphalted oil under fluid catalytic cracking conditions further comprises processing a vacuum gas oil boiling range feed under the fluid catalytic cracking conditions. 
     
     
         10 . The method of  claim 8 , wherein processing the at least a portion of the hydroprocessed deasphalted oil under fluid catalytic cracking conditions forms at least a catalytic slurry oil fraction, at least a portion of the catalytic slurry oil fraction being used as the co-feed for the hydroprocessing of the deasphalter rock. 
     
     
         11 . The method of  claim 8 , wherein processing the at least a portion of the hydroprocessed deasphalted oil under fluid catalytic cracking conditions forms at least a light cycle oil fraction having a final boiling point or T95 boiling point of about 650° F. (˜343° C.) or less, at least a portion of the light cycle oil fraction being used as an aromatic solvent for the hydroprocessing of the deasphalter rock. 
     
     
         12 . The method of  claim 1 , wherein the deasphalter rock comprises at least about 10 wt % n-heptane insolubles, the hydroprocessed effluent comprising about 50% or less of the n-heptane insolubles in the feedstock exposed to the fixed bed hydroprocessing catalyst. 
     
     
         13 . The method of  claim 1 , wherein the effective hydroprocessing conditions are effective for conversion of at least about 40 wt % of the 1050° F.+(566° C.+) portion of the deasphalter rock. 
     
     
         14 . The method of  claim 1 , wherein the effective hydroprocessing conditions for conversion of the deasphalter rock comprise a temperature of about 371° C. to about 433° C. and a total pressure of about 600 psig (˜4.2 MPag) to about 6000 psig (˜42 MPag). 
     
     
         15 . The method of  claim 1 , further comprising hydrotreatment of at least a portion of the deasphalted oil fraction, a combined conversion of the at least a portion of the deasphalted oil fraction and the (at least a portion of the) deasphalter rock fraction relative to 1050° F. (566° C.) being at least about 60 wt %. 
     
     
         16 . The method of  claim 1 , wherein the hydroprocessed effluent has a micro-carbon residue content that is about 50% or less of a micro-carbon residue content in the feedstock exposed to the fixed bed hydroprocessing catalyst. 
     
     
         17 . A method for fixed bed processing of deasphalter rock, comprising:
 performing solvent deasphalting on a resid feedstock to form a deasphalter rock fraction and a deasphalted oil fraction, the resid feedstock having a T10 distillation point of at least about 650° F. (˜343° C.), the deasphalter rock fraction comprising at least about 10 wt % of the resid feedstock; and   exposing a feedstock comprising at least a portion of the deasphalter rock fraction to a fixed bed of hydroprocessing catalyst under hydroprocessing conditions effective for conversion of at least 40 wt % of the at least a portion of the deasphalter rock relative to a conversion temperature of 1050° F. (566° C.) to form a hydroprocessed effluent, the feedstock comprising at least about 10 wt % of the at least a portion of the deasphalter rock.   
     
     
         18 . The method of  claim 17 , wherein performing solvent deasphalting on the resid feedstock comprises performing propane deasphalting on the resid feedstock. 
     
     
         19 . The method of  claim 17 , further comprising solvent processing at least a portion of the deasphalted oil fraction to form a Group I lubricant base stock. 
     
     
         20 . A hydrotreated effluent formed from processing of deasphalter rock, the hydrotreated effluent formed by the method comprising:
 exposing a feedstock comprising deasphalter rock and a co-feed comprising a catalytic slurry oil, a lubes extract, a heavy coker gas oil, a vacuum gas oil derived from a heavy oil, or a combination thereof, to a fixed bed of hydroprocessing catalyst under hydroprocessing conditions effective for conversion of at least 40 wt % of the deasphalter rock relative to a conversion temperature of 1050° F. (566° C.) to form a hydroprocessed effluent, the feedstock comprising at least about 20 wt % of the co-feed and at least about 10 wt % of the deasphalter rock.