Process scheme for maximum heavy oil conversion with stage asphaltene rejection

A system to upgrade an input stream, comprising:

• an input stream of a straight run atmospheric residue or a cracked feedstock;
• a vacuum column;
• a hydrocracking unit coupled downstream of and in fluid communication with the vacuum column;
• a high lift solvent deasphalting unit coupled downstream of and in fluid communication with the vacuum column;
• a low lift solvent deasphalting unit coupled downstream of and in fluid communication with the vacuum column;
• and
• a pitch pelletizing unit coupled downstream of and in fluid communication with the high lift solvent deasphalting unit,
• where:
• the vacuum column is configured to receive the input stream and to separate the input stream into a vacuum column light stream and a vacuum residue stream,
• the hydrocracking unit is configured to receive a combined stream of the vacuum column light stream and a heavy deasphalted oil stream, as well as a hydrogen stream, and to pass a distillate and naphtha product, and a light ends product,
• the heavy deasphalted oil stream is in fluid communication with the hydrocracking unit and also with the high lift solvent deasphalting unit,
• the high lift solvent deasphalting unit is configured to receive a butane stream, as well as a combined stream of a first portion of the vacuum residue stream, an unconverted oil stream as a hydrocracking bleed stream, and a heavy oil stream, and to pass an asphaltene-lean heavy deasphalted oil stream and an asphaltene-rich pitch stream,
• the unconverted oil stream is in fluid communication with the hydrocracking unit and the high lift solvent deasphalting unit,
• the low lift solvent deasphalting unit is configured to receive a propane stream, as well as a combined stream of a second portion of the vacuum residue stream, and to pass a light deasphalted oil that is a lube base feed stock, and a heavy oil stream,
• the heavy oil stream is in fluid communication with the high lift solvent deasphalting unit,
• the pitch pelletizing unit is configured to receive an asphaltene-rich pitch stream, and to pass a solid fuel,
• the asphaltene-rich pitch stream is in fluid communication with the high lift solvent deasphalting unit and the pitch pelletizing unit, and
• the vacuum residue stream is in parallel to the high lift solvent deasphalting unit and the low lift solvent deasphalting unit.

A system to upgrade an input stream, comprising:

• an input stream of a straight run atmospheric residue or a cracked feedstock;
• a vacuum column;
• a hydrocracking unit coupled downstream of and in fluid communication with the vacuum column;
• a high lift solvent deasphalting unit coupled downstream of and in fluid communication with the vacuum column;
• a low lift solvent deasphalting unit coupled downstream of and in fluid communication with the high lift solvent deasphalting unit;
• a hydrotreating reactor coupled downstream of and in fluid communication with the high lift solvent deasphalting unit and the low lift solvent deasphalting unit;
• and
• a bitumen blowing unit coupled downstream of and in fluid communication with the vacuum column and the high lift solvent deasphalting unit,
• where:
• the vacuum column is configured to receive the input stream and to separate the input stream into a vacuum column light stream and a vacuum residue stream
• the hydrocracking unit is configured to receive a hydrogen stream, as well as a combined stream of the vacuum column light stream and an effluent from the hydrotreating reactor, and to pass a distillate and naphtha product, and a light ends product,
• the effluent from the hydrotreating reactor is in fluid communication with the hydrocracking unit as an effluent hydrocracking feed stream, and is also in fluid communication with the hydrotreating reactor,
• the high lift solvent deasphalting unit is configured to receive a butane stream, as well as a combined stream of a first portion of the vacuum residue stream, and a first portion of a hydrocracking bleed stream, and to pass an asphaltene-lean heavy deasphalted oil stream and an asphaltene-rich pitch stream, an unconverted oil stream is in fluid communication with the hydrocracking unit, the high lift solvent deasphalting unit, and the bitumen blowing unit,
• the low lift solvent deasphalting unit is configured to receive a propane stream, as well as a first portion of the asphaltene-lean heavy deasphalted oil stream, and to pass a light deasphalted oil that is a lube base feed stock, and a heavy oil stream, the heavy oil stream is in fluid communication with the hydrotreating reactor,
• the hydrotreating reactor is configured to receive a hydrogen stream, as well as a combined stream of a second portion of the asphaltene-lean heavy deasphalted oil stream, and the heavy oil stream, and to pass a light ends product,
• the bitumen blowing unit is configured to receive a combined stream of a second portion of the hydrocracking bleed stream, a second portion of the vacuum residue stream, the asphaltene-rich pitch stream, and a low viscosity gas oil stream, and to pass a bitumen and asphalt stream,
• the low viscosity gas oil stream is in fluid communication with the bitumen blowing unit, and
• the vacuum residue stream is in parallel to the high lift solvent deasphalting unit and the bitumen blowing unit.

A process, comprising:

• introducing a straight run atmospheric residue or a cracked feed stock into a system;
• and
• operating the system including a step of fractionating, a step of solvent stage deasphalting, and a step of hydrocracking,
• where the step of fractionating includes operating the system such that a fractionated distillate, a gas oil product, and a vacuum residue are produced from a vacuum column with an input of the straight run atmospheric residue or the cracked feed stock, and combining the fractionated distillate and the gas oil product into a single internal stream as a vacuum column lights stream,
• where the step of solvent stage deasphalting includes operating the system such that an asphaltene-lean heavy deasphalted oil and an asphaltene-rich pitch are produced from a high-lift solvent deasphalting unit with an input of a combined internal stream of vacuum residue and unconverted oil,
• where the step of solvent stage deasphalting further includes operating the system such that a light deasphalted oil, which is a lube base feed stock, and a heavy oil are produced from a low-lift solvent deasphalting unit with an input of vacuum residue or an asphaltene-lean heavy deasphalted oil, and
• where the step of hydrocracking includes operating the system such that a naphtha product and an unconverted oil are produced from a hydrocracking unit with an input of a combined internal stream of a vacuum residue and an asphaltene-lean heavy deasphalted oil.