DESC:FIELD
The present disclosure relates to a process for production of hydrocarbon fuels. Particularly, the present disclosure relates to a process for production of middle distillates.
DEFINITIONS
As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicates otherwise.
Pitch refers to a black or dark brown colored residue formed during the process of crude oil distillation or upgradation of heavier hydrocarbons.
Middle distillates refer to petroleum products obtained in the “middle” boiling range from about 180°C to 370°C during the process of crude oil distillation.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
The global demand for distillates is growing exponentially. Conventionally, in petroleum refineries, distillation units are used for transforming crude oil into valuable fuel products having different boiling fractions. These straight run products are separated and treated by using different processes in order to meet the product quality that can be marketed.
In order to maximize the yield of such distillates, hydrocracking process is used to convert heavy hydrocarbons into more valuable distillates under hydrogen atmosphere.
The process like ‘vis-breaking’ is also used for further converting the bottoms to distillates and fuel oil. In the visbreaking process, vacuum resid fraction is thermally cracked to provide products having lower viscosities, typically unsaturated aromatics. During thermal cracking, the aromatics condense to form polynuclear aromatics resulting in coke formation. The products need to meet stability for using it as fuel oil. In order to meet the product specifications, usually cutter stocks are added, which leads to reduction in the overall production of distillates in the refinery.
There are also processes like Delayed Coker and Resid FCC which can convert the vacuum residue to lighter distillates. Each of these processes are designed to meet the required product specifications and quality. However, these processes produce considerable quantities of pitch.
There is, therefore, felt a need for an alternative process that increases the yield of valuable middle distillates, reduces the coke formation and minimizes pitch formation.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows.
It is an object of the present disclosure to ameliorate one or more problems of prior art or to at least provide a useful alternative.
An object of the present disclosure is to provide a process for increased production of middle distillates.
Another object of the present disclosure is to provide a process for production of middle distillates with reduced coke formation.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure relates to a process for producing middle distillates from vacuum residue. First, the vacuum residue feed stream is obtained. A first predetermined amount of the vacuum residue feed stream is hydrocracked in mild hydrocracking unit (MHCU) at a first predetermined conditions for a first predetermined time period by using hydrogen gas in the presence of a first catalyst to obtain a first product mixture comprising LPG, naphtha, middle distillates, VGO and bottom product having boiling point greater than 540 °C.
The bottom product having boiling point greater than 540 °C is separated from the first product mixture to obtain a separated bottom product having boiling point greater than 540 °C.
The separated bottom product having boiling point greater than 540 °C, is mixed to a second predetermined amount of the vacuum residue feed stream to obtain a resultant mixture. The resultant mixture is then hydrocracked in a resid hydrocracking unit (RHCU) at a second predetermined conditions for a second predetermined time period by using hydrogen gas in the presence of a second catalyst, to obtain a second product mixture comprising middle distillates. The second product mixture is then fractionated to obtain the middle distillates.
In an embodiment the vacuum residue feed stream is obtained by using a heavy hydrocarbon feed. The heavy hydrocarbon feed is separated in an atmospheric distillation unit (ADU) to obtain an overhead stream and an atmospheric residue stream. The atmospheric residue stream is then fractionated in a vacuum distillation unit (VDU) to obtain a vacuum distillate and the vacuum residue feed stream.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
The present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates a schematic representation of process for production of middle distillates from a heavy hydrocarbon feed, in accordance with the present disclosure.
LIST OF REFERENCE NUMERALS
References Reference Numeral
Hydrocarbon Feed 1
Atmospheric Distillation Unit (ADU) 2
Vacuum Distillation Unit (VDU) 3
Mild hydrocracking unit (MHCU) 4
Catalyst Tank 5
Hydrogen Tank 6
Resid Hydrocracking Unit (RHCU) 7
Middle Distillates fraction 8a and 8b

DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc. when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
The present disclosure provides a process, for upgrading heavy hydrocarbons in a refinery to obtain middle distillates from vacuum residue.
The present disclosure provides a simple and economical process for production of middle distillates with reduced formation of coke as well as reduced formation of pitch. The process disclosed herein provides a flexibility for producing bitumen as one of the products in addition to maximizing middle distillates production. The process of the present disclosure is described in detail with the reference to Figure 1 herein below:
The vacuum residue feed stream is obtained from a heavy hydrocarbon feed (1). The heavy hydrocarbon feed (1) is fed to an atmospheric distillation unit (ADU) (2) to separate into an overhead stream comprising light distillates and middle distillates, and an atmospheric residue stream.
The atmospheric residue stream is further subjected to a vacuum distillation unit (VDU) (3) for the separation of atmospheric residue stream into vacuum distillates, vacuum gas oil and the vacuum residue feed stream.
In accordance with the embodiments of the present disclosure, a first predetermined amount of the vacuum residue feed stream obtained from the vacuum distillation unit (VDU) (3) is fed to mild hydrocracking unit (MHCU) (4).
In an embodiment, the mild hydrocracking unit (MHCU) (4) is modified by incorporation of catalyst and hydrogen gas into a vis-breaking unit, also referred as the modified vis-breaking unit (VBU).
In accordance with the present disclosure, the mild hydrocracking unit (MHCU) (4) is adapted to carry out mild hydrocracking of the first predetermined amount of the vacuum residue feed stream to obtain a product mixture/stream rich in middle distillates (8a) and bottom product having a boiling point greater than 540 °C. The bottoms product comprises partially converted vacuum residue. The first predetermined amount of the vacuum residue feed stream is mildly hydrocracked under first predetermined cracking conditions in the presence of a first catalyst contained in the catalyst tank (5) and hydrogen contained in the hydrogen tank (6).
In an embodiment, the first predetermined cracking conditions includes the operating temperature of the mild hydrocracking unit (MHCU) (4) in the range of 350 °C to 450 °C, more preferentially 385 °C to 430 °C to obtain distillate products. The operating hydrogen pressures of the mild hydrocracking unit (MHCU) (4) is in the range of 5 bar to 80 bar, more preferably in the range of 10 bar to 50 bar. The liquid hourly space velocity (LHSV) of the mild hydrocracking unit (MHCU) (4) is in the range of 0.5 to 12 h-1, more preferably in the range of 1 to 6 h-1. The time period of the mild hydrocracking of the first predetermined amount of the vacuum residue feed stream is in the range of 10 minutes to 30 minutes.
In an exemplary embodiment, the first hydrocracking conditions include the temperature is 420 °C, pressure is 15 bar, and time period is 20 min.
In another embodiment, the conversion of the first predetermined amount of the vacuum residue in the mild hydrocracking unit is in the range of 20 wt% - 60 wt%. The yield of the middle distillate from the mild hydrocracking unit is in the range of 25 wt% to 45 wt%. Bitumen from the mild hydrocracking unit is in the range of 55 wt% - 75 wt%.
In an embodiment, the first predetermined amount of the vacuum residue feed stream is in the range of 50 wt% to 100 wt%. The volume ratio of hydrogen at normal condition from the hydrogen tank (6) to the first predetermined amount of the vacuum residue stream is in the range of 50 to 1000 and more preferably in the range of 100 to 800. In an exemplary embodiment, the volume ratio is 400.
Further, the bottom product comprising partially converted vacuum residue obtained from the mild hydrocracking unit (MHCU) (4) is separated to obtain a separated bottom product. The separated bottom products are mixed with a second predetermined amount of the vacuum residue feed stream to obtain a resultant mixture.
In accordance with the present disclosure, the resultant mixture is fed to a resid hydrocracking unit (RHCU) (7) and hydrocracking is carried out at a second predetermined conditions for a second predetermined time period to obtain a second product mixture. In the resid hydrocracking unit (RHCU) (7), the severity of the vacuum residues from the vacuum distillation unit (VDU) (3) is diluted due to the addition of the partially converted vacuum residue from mild hydrocracking unit (MHCU) (4).
In an embodiment, the moderate to severe second predetermined conditions at RHCU (7) in the presence of a second catalyst contained in the catalyst tank (5) and hydrogen contained in the hydrogen tank (6) help in increasing the yield of the middle distillates along with reduction in coke/ pitch formation. The product stream (8b) obtained from the RHCU (7) comprises middle distillates with increased yield. The partially converted vacuum resid from the modified VBU or MHCU is a bitumen grade product. The integration of MHCU and RHCU units offer the wide range of products from LPG, middle distillates, VGO and Bitumen with less coke and Pitch.
In an embodiment, the second predetermined conditions include the operating temperature of the resid hydrocracking unit (RHCU) (7) in the range of 360 °C to 480 °C, more preferentially 400 °C to 460 °C. The operating hydrogen pressures of RHCU (7) is in the range of 80 bar to 220 bar, more preferably in the range of 100 bar to 180 bar. The liquid hourly space velocity (LHSV) of the RHCU (7) is in the range of 0.1 to 1 h-1, more preferably in the range of 0.16 to 0.5 h-1. The time period in resid hydrocracking unit (RHCU) is in the range of 1 hour to 10 hours.
In an exemplary embodiment, the first hydrocracking conditions include the temperature is 420 °C, pressure is 15 bar, LHSV is 3.33h-1 and time period is 20 min.
In another embodiment, the conversion in the resultant mixture in the resid hydrocracking unit is in the range of 65 wt% - 98 wt%. The yield of the middle distillate from the resid hydrocracking unit is in the range of 60 wt% to 90 wt%.
In an embodiment, the second predetermined amount of the vacuum residue feed stream is in the range of 50 wt% to 80 wt%. The volume ratio of hydrogen at normal condition from the hydrogen tank (6) to the second predetermined amount of the vacuum residue feed stream is in the range of 200 to 3000 and more preferably in the range of 500 to 2000. In an exemplary embodiment, the volume ratio is 1000.
In accordance with the embodiments of the present disclosure, the first and the second catalyst contained in the catalyst tank (5) is used in resid hydro-cracker unit (RHCU) and mild hydrocracking unit (MHCU) respectively are introduced in at least one form selected from the group consisting of colloidal dispersed form, slurry phase dispersed form, extrudated form, water soluble form and oil soluble catalyst form.
In accordance with the embodiments of the present disclosure, the first catalyst and the second catalyst are same or different and comprise at least one metal or at least one metal compound of a metal selected from the group consisting of iron, cobalt, nickel, molybdenum, and tungsten.
In an exemplary embodiment, the first catalyst is molybdenum oil soluble catalyst and the second catalyst is molybdenum oil soluble catalyst.
In an exemplary embodiment, metal in the first catalyst contained in the catalyst tank (5) is in the range of 10 ppm to 15,000 ppm and more preferably in the range of 50 ppm to 2000 ppm. In an exemplary embodiment, the amount of first catalyst is molybdenum oil soluble catalyst.
Metal in the second catalyst contained in the catalyst tank (5) is in the range of 100 ppm to 20000 ppm and more preferably in the range of 500 ppm to 10000 ppm. In an exemplary embodiment, the amount of second catalyst is 10000 ppm.
In accordance with an embodiment of the present disclosure, the resid hydrocracking unit comprises bubble reactors and ebullated bed reactors in at least one configuration selected from the group consisting of series, parallel and series-parallel.
In accordance with the embodiments of the present disclosure, the process of the present disclosure is a continuous process or a batch process.
The process of the present disclosure is capable of obtaining middle distillates with increased yield, Bitumen as additional product and with reduced formation of coke/ pitch by processing bottoms obtained from MHCU comprising partially cracked vacuum residue along with bottoms obtained from VDU. The partially converted vacuum resid from the mild hydrocracking unit is a bitumen grade product. Based on demand of bitumen or distillates, the process flexibility to change the feed in resid hydrocracking unit with split between vacuum residue and bottom product from mild hydrocracker unit. The combination of MHCU and RHCU units offer the wide range of products from LPG, middle distillates (180 -370 °C), VGO (370-540 °C) with less coke and Pitch (> 540 °C fraction). The reaction time used is in the range of 1-10 hrs, more preferably in the range of 1.5-6 hrs.
The present disclosure further provides a system for production of hydrocarbon fuels with low coke formation comprising atmospheric distillation unit (2), vacuum distillation unit (3), mild hydrocracking unit (4), resid hydrocracking unit (7), a catalyst tank (5) and a hydrogen tank (6). The integration of MHCU and RHCU units offer the wide range of products from LPG, middle distillates, VGO and Pitch.
The present disclosure is further described in light of the following experiments which are set forth for illustration purpose only and not to be construed for limiting the scope of the disclosure. The following experiments can be tested to scale up to industrial/commercial scale and the results obtained can be extrapolated to industrial scale.
EXAMPLES
Example 1
This experiment describes the mild hydrocracking process of Basrah vacuum residue in presence of hydrogen and slurry dispersed catalyst in a stirred tank reactor. The feed consist of 86 wt% of 540 °C above boiling material. Resid hydrocracking experiment conducted with mixture of vacuum residue and bottom product of mild hydrocracking (540+ fraction) after separation of distillates.
Firstly, reactor was loaded with Basrah vacuum residue along with molybdenum oil soluble catalyst concentration of 500 ppm metal. Then the reactor was purged with nitrogen and later was pressurized with Hydrogen at 15 bar. The reaction mixture was heated to 420 °C. Hydrogen to vacuum residue volume ratio was 400. The mild hydrocracking process reactions take place whenever the reactor temperature is above 380 °C in presence of hydrogen. The reaction was carried out for a period of 20 minutes maintaining the reaction temperature at 410 °C. After reaction, the reactor products are cooled by circulating chilled water to bring down the temperature below 30 °C. The gaseous products are analyzed using Gas Chromatograph for its composition. The liquid sample is collected and analyzed in GC-SIMDIST as per ASTM D-7169. The products are fractionated in Minipotstill apparatus to get the individual product cuts.
Example 2
For comparison of product cut yields, full resid hydrocracking experiment is conducted with vacuum residue without mixing any other products. The reactor was loaded with Basrah vacuum residue along with catalyst concentration of 10000 ppm of molybdenum oil soluble catalyst. Then the reactor was purged with nitrogen and later was pressurized with Hydrogen in the range of 120 bar. Hydrogen to vacuum residue volume ratio was 1000. The reaction mixture was heated to 430 °C. The reaction was carried out for a period of 3 hours maintaining the reaction temperature at 430 °C. After reaction, the recovery, fractionation, and product characterization is carried out as mentioned in example 1.
Example 3
The resid hydrocracking experiment conducted with combined feed with a portion of bottom from mild hydrocracking unit as obtained from example 1 and another portion of vacuum residue from vacuum distillation unit. In a typical experiment, 250 g of feed consist of a portion 160 g of bottom product as recovered from example-1 and 90 g of virgin vacuum residue is fed into the reactor. The temperature used in this reaction is 420 °C with hydrogen pressure of 120 bar. The catalyst concentration used in this reaction is 10000 ppm of molybdenum oil soluble catalyst. The reaction time used in this reaction is 3 hrs. After reaction, the recovery, fractionation, and product characterization is carried out as mentioned in example 1.
The results obtained for mild hydrocracking process for distillates and combination of mild and resid hydrocracking process are provided in Table 1.
Table 1
Feed (vacuum residue) Results according to example-1 Results according to example-2 Results according to example-3
Product Yields (Wt%) Product Yields (Wt%) Product Yields (wt%)
Gas 3.8 15.3 11.3
LPG 0.3 3.4 1.9
Naphtha (<180 °C) 3.5 19.5 12.2
Distillates (180-370 °C) 4.2 40.2 29.8
VGO (370-540 °C) 14 22.5 11.9 31.0
Unconverted Residue (540 °C+), Bitumen range material 86 65.6 9.1 13.7
Conversion % 35 90.4 86.2
Mild hydrocracking for distillates results in liquid yields of ~ 49% and bottom product yield of ~26 % with conversion of 35%. Combined mild and resid hydrocracking process results in increasing the liquid yield to ~73% with conversion of ~86%.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
The functions described herein may be implemented in hardware, software executed by a processor, firmware, or any combination thereof. If implemented in software executed by a processor, the functions may be stored on or transmitted over as one or more instructions or code on a computer- readable medium. Other examples and implementations are within the scope and spirit of the disclosure and appended claims. For example, due to the nature of software, functions described above can be implemented using software executed by a processor, hardware, firmware, hardwiring, or combinations of any of these. Features implementing functions may also be physically located at various positions, including being distributed such that portions of functions are implemented at different physical locations.
In addition, any disclosure of components contained within other components or separate from other components should be considered exemplary because multiple other architectures may potentially be implemented to achieve the same functionality, including incorporating all, most, and/or some elements as part of one or more unitary structures and/or separate structures.
The functions described herein may be implemented in hardware, software executed by a processor, firmware, or any combination thereof. If implemented in software executed by a processor, the functions may be stored on or transmitted over as one or more instructions or code on a computer- readable medium. Other examples and implementations are within the scope and spirit of the disclosure and appended claims. For example, due to the nature of software, functions described above can be implemented using software executed by a processor, hardware, firmware, hardwiring, or combinations of any of these. Features implementing functions may also be physically located at various positions, including being distributed such that portions of functions are implemented at different physical locations.
In addition, any disclosure of components contained within other components or separate from other components should be considered exemplary because multiple other architectures may potentially be implemented to achieve the same functionality, including incorporating all, most, and/or some elements as part of one or more unitary structures and/or separate structures.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a process for production of the middle distillates from vacuum residue, which:
• provides middle distillates with increased yield and with reduced coke formation; and
• is simple and economical.
ECONOMIC SIGNIFICANCE, Section 2(1)(ja)
One of the object of the Patent Law is to provide protection to new technologies in all fields and domain of technologies. The new technologies shall or may contribute in the country economy growth by way of involvement of new efficient and quality method or product manufacturing in India.
To provide the protection of new technologies by patenting the product or process will contribute significant for innovation development in the country. Further by granting patent the patentee can contribute in manufacturing the new product or new process of manufacturing by himself or by technology collaboration or through the licensing.
The applicant submits that the present disclosure will contribute in country economy, which is one of the purposes to enact the Patents Act, 1970. The product in accordance with present invention will be in great demand in country and worldwide due to novel technical features of a present invention is a technical advancement in providing middle distillates with increased yield and with reduced coke formation. The technology in accordance with present disclosure will provide product cheaper, saving in time of total process of manufacturing. The saving in production time will improve the productivity, and cost cutting of the product, which will directly contribute to economy of the country.
The process will contribute new concept in the field for production of hydrocarbon fuels, wherein patented process will be used. The present disclosure will replace the whole concept of production of considerable quantities of pitch being generated in petroleum refineries from decades. The process is developed in the national interest and will contribute to country economy.
The economy significance details requirement may be called during the examination. Only after filing of this Patent application, the applicant can work publically related to present disclosure product/process/method. The applicant will disclose all the details related to the economic significance contribution after the protection of invention.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully revealed the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

,CLAIMS:We Claim:

1. A process for production of middle distillates from vacuum residue; wherein said process comprising the following steps:
a) obtaining said vacuum residue feed stream;
b) hydrocracking a first predetermined amount of said vacuum residue feed stream in a mild hydrocracking unit (MHCU) (4) at a first predetermined conditions for a first predetermined time period by using hydrogen gas in the presence of a first catalyst to obtain a first product mixture comprising LPG, naphtha, middle distillates, VGO and bottom product having boiling point greater than 540 °C;
c) separating said bottom product from said first product mixture to obtain a separated bottom product having boiling point greater than 540 °C;
d) mixing said separated bottom product in a second predetermined amount of said vacuum residue feed stream to obtain a resultant mixture;
e) hydrocracking said resultant mixture in a resid hydrocracking unit (RHCU) (7) at a second predetermined conditions for a second predetermined time period by using hydrogen gas in the presence of a second catalyst, to obtain a second product mixture comprising middle distillates; and
f) fractionating said second product mixture to obtain said middle distillates.

2. The process as claimed in claim 1, wherein said vacuum residue feed stream is obtained by:
i. separating a heavy hydrocarbon feed (1) in an atmospheric distillation unit (ADU) (2) to obtain an overhead stream and an atmospheric residue stream; and
ii. fractionating said atmospheric residue stream in vacuum distillation unit (VDU) (3) to obtain a vacuum distillate and said vacuum residue feed stream.

3. The process as claimed in claim 1, wherein said first predetermined amount of said vacuum residue feed stream is in the range of 50 wt% to 100 wt%.

4. The process as claimed in claim 1, wherein said second predetermined amount of said vacuum residue is in the range of 50 wt% to 80wt%.

5. The process as claimed in claim 1, wherein said first pre-determined conditions include a temperature in the range of 350 °C to 450 °C, a pressure in the range of 5 bar to 80 bar, and an LHSV in the range of 0.5 to 12 h-1.

6. The process as claimed in claim 1, wherein said first pre-determined time period is in the range of 10 minutes to 30 minutes.

7. The process as claimed in claim 1, wherein said first catalyst and said second catalyst is introduced in at least one form selected from the group consisting of colloidal dispersed form, slurry phase dispersed form, extrudated form, water soluble form and oil soluble catalyst form.

8. The process claimed in claim 7, wherein said first catalyst and said second catalyst are same or different and comprises at least one metal selected from the group consisting of iron, cobalt, nickel, molybdenum, and tungsten.

9. The process as claimed in claim 8, wherein the amount of said metal in said first catalyst is in the range of 10 ppm to 15,000 ppm.

10. The process as claimed in claim 8, wherein the amount of said metal in said second catalyst is in the range of 100 ppm to 20000 ppm.

11. The process as claimed in claim 1, wherein the volume ratio of hydrogen to said first predetermined amount of said vacuum residue feed stream is in the range of 50 to 1000.

12. The process as claimed in claim 1, wherein said second pre-determined conditions include a temperature in the range of 360 °C to 480 °C, a pressure in the range of 80 bar to 220 bar, and an LHSV in the range of 0.1 to 1 h-1.

13. The process as claimed in claim 1, wherein said second pre-determined time period is in the range of 1 hour to 10 hours.

14. The process as claimed in claim 1, wherein the volume ratio of hydrogen to said second predetermined amount of said vacuum residue feed stream is in the range of 200 to 3000.

15. The process as claimed in claim 1, wherein said resid hydrocracking unit comprises bubble column reactors and ebullated bed reactors in at least one configuration selected from the group consisting of series configuration, parallel combination and combination thereof.

16. The process as claimed in claim 1, wherein the conversion of said resultant mixture is in the range of 65 % to 98 %.

17. The process as claimed in claim 1, wherein said fractionating of said second product mixture to obtain naphtha, diesel and vacuum gas oil along with middle distillate.

18. The process as claimed in claim 1, wherein yield of said middle distillate is in the range of 60 wt% to 90 wt%.

Dated this 4th Day of July, 2020

MOHAN RAJKUMAR DEWAN
of R.K. DEWAN & COMPANY
IN/PA-25
APPLICANT’S PATENT ATTORNEY

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT MUMBAI