Process and system for conversion of crude oil to petrochemicals and fuel products integrating vacuum residue conditioning and base oil production

An integrated process for producing petrochemicals and fuel products from a crude oil feed comprising:

• separating from the crude oil feed, in an atmospheric distillation unit (ADU), at least a first ADU fraction comprising straight run naphtha,
• a second ADU fraction comprising at least a portion of middle distillates from the crude oil feed, and
• a third ADU fraction comprising atmospheric residue;
• separating from the third ADU fraction, in a vacuum distillation unit (VDU), at least a first VDU fraction comprising vacuum gas oil;
• hydroprocessing in a distillate hydroprocessing (DHP) zone middle distillates from the second ADU fraction, and recovering at least a first DHP fraction and a second DHP fraction, wherein the first DHP fraction comprises naphtha and the second DHP fraction is used for diesel fuel production;
• hydroprocessing in a gas oil hydroprocessing (GOHP) zone vacuum gas oil from the first VDU fraction, and recovering a first GOHP fraction containing components boiling at or below an atmospheric residue end boiling point and including LPG, naphtha and middle distillate range components, and a second GOHP fraction containing heavy oil, which is hydrotreated gas oil or unconverted oil in the vacuum gas oil range;
• steam cracking, in a mixed feed steam cracking (MFSC) zone, naphtha from the first ADU fraction and raffinate derived from an aromatics extraction zone, wherein steam cracking in the MFSC zone operates conditions effective to recover a mixed product stream comprising H2, methane, ethane, ethylene, mixed C3s and mixed C4s;
• pyrolysis gas;
• and pyrolysis oil;
• recovering, from the mixed product stream, H2, methane, non-olefinic C2-C4s, and petrochemicals ethylene, propylene and butylenes,
• hydroprocessing pyrolysis gas from steam cracking in a naphtha hydroprocessing zone, and recovering hydrotreated pyrolysis gas;
• separating aromatics from hydrotreated pyrolysis gas in the aromatics extraction zone for recovery of petrochemical aromatic products, and aromatics extraction zone raffinate, wherein the raffinate derived from aromatics extraction is all or a portion of the aromatics extraction zone raffinate;
• and
• processing heavy oil in the vacuum gas oil range from the GOHP zone in a base oils production center, including catalytic dewaxing and hydrofinishing operations, and recovering base oils product.