DESC:FIELD
The present disclosure relates to an integrated vacuum residue hydrocracking process.
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.
Penetration value determines the hardness or softness of bitumen by measuring the distance in millimeter to which a standard loaded needle will penetrate vertically in five seconds while the temperature of the bitumen sample is maintained at 25 oC..
If penetration value is N, Distance penetrated = (N/10) mm.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Typically, a hydrocarbon feed is distilled to obtain distillates, vacuum gas oil and vacuum residue. The higher boiling vacuum residue is further cracked thermally in a visbreaking unit (VBU), to form visbreaking gas oil (VBGO) and visbreaking tar (VB Tar). The VB tar is mixed with VBGO and additional cutter stocks to make fuel oil. The yield of distillates from the VBU is very less as most of them are blended back with VB Tar to meet the specifications of fuel oil (FO).
The sulphur content in the distillates and fuel oil obtained by the use of VBU is usually very high. In case, the demand for low sulfur fuel oil (LSFO) increases, a standalone VBU would not be effective. Moreover, the fuel oil needs hydrotreatment to meet the LSFO specifications. The use of two separate units i.e. a VBU and a unit for standalone hydrotreatment of FO, would add to the total cost of the process.
There is, therefore, felt a need for a simple and economical process for hydrocracking of vacuum residue that mitigates the drawbacks mentioned hereinabove.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are as follows.
An object of the present disclosure is to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
Another object of the present disclosure is to provide an integrated process of hydrocracking vacuum residue for producing bitumen grade bottom products and other distillates.
Yet another object of the present disclosure is to provide a simple and efficient process for hydrocracking of the vacuum residue, that reduces 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 an integrated process of hydrocracking vacuum residue for producing bitumen grade bottom products having a penetration value in the range of 35 to 80, a kinematic viscosity in the range of 250 to 400 centistokes, a softening point in the range of 40 oC to 50 oC and a ductility in the range of 25 to 75. The process comprises obtaining a first predetermined amount of the vacuum residue stream and hydrocracking it in a resid hydrocracking unit (9) (RHCU) at a first pre-determined conditions for a first pre-determined time period by using hydrogen gas (6) in the presence of a catalyst (5) to obtain a first product mixture comprising a first distillate, a vacuum gas oil and a gaseous mixture. The vacuum gas oil and the gaseous mixture is separated from the first product mixture to obtain a separated gaseous mixture and a separated vacuum gas oil. The separated gaseous mixture and the separated vacuum gas oil is mixed to a second predetermined amount of the vacuum residue stream to obtain a resultant mixture. The resultant mixture is then hydrocracked in a mild hydrocracking unit (4) (MHC) under a second pre-determined conditions for a second pre-determined time period to obtain a second product mixture comprising a second distillate and the bitumen grade bottom product. The second product mixture is then fractionated (7) to obtain the bitumen grade bottom products (10).
In an embodiment the vacuum residue stream is obtained from a heavy hydrocarbon feed. First, the heavy hydrocarbon feed (1) is separated in an atmospheric distillation unit (2) (ADU) to obtain an overhead stream and an atmospheric residue stream. The atmospheric residue stream is then fractionated in a vacuum distillation unit (3) (VDU) to obtain a vacuum distillate and a vacuum residue 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 for the flow-path of the process in accordance with the present disclosure
List of Reference Numerals
Hydrocarbon feed 1
Atmospheric Distillation Unit (ADU) 2
Vacuum Distillation Unit (VDU) 3
Mild hydrocracking unit 4
Catalyst Tank 5
Hydrogen Tank 6
Fractionation unit 7
Middle distillates 8
Resid hydrocracking unit 9
Bitumen grade bottom product 10

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.
Conventionally, hydrocarbon distillation is associated with formation of vacuum residue which is processed in a visbreaker unit (VBU) to obtain valuable middle distillates and tar. The middle distillates mainly comprise naphtha and gas oils which are used for forming fuel oil. However, the conventional VBU uses thermal cracking thereby leading to the formation of undesirable coke if the process severity is increased to make more distillates. The objective of VBU is only to reduce the viscosity of vacuum residue and make fuel oil by blending it with cutter stocks.
In order to maximize the yield of distillates from vacuum residue, conventional hydrocracking units such as slurry hydrocrackers (SHCU) are preferred. The hydrocracking process is carried out by using hydrogen in the presence of a catalyst which provides suitable conditions, thereby maximizing the conversions of vacuum residue to middle distillates and reducing the amount of coke formation. The slurry hydrocracking unit (SHCU) involves a liquid phase comprising finely dispersed catalyst.
However, by virtue of the higher conversions, the conventional SHCU results in higher formation of middle distillates and pitch as the bottom product.
The present disclosure provides an integrated process of hydrocracking vacuum residue for producing bitumen grade bottom products having a penetration value in the range of 35 to 80, a kinematic viscosity in the range of 250 to 400 centistokes, a softening point in the range of 40 oC to 50 oC and a ductility in the range of 25 to 75.
The process is described in detail below:
First, a vacuum residue stream is obtained.

In accordance with the embodiments of the present disclosure, the vacuum residue stream is obtained by the following steps:

A heavy hydrocarbon feed is separated in an atmospheric distillation unit (ADU) to obtain an overhead stream and an atmospheric residue stream.

The atmospheric distillation is used for separating one or more hydrocarbon fractions of different boiling points from a crude hydrocarbon fraction. Main components from this process are gaseous products, distillate fractions such as kerosene, diesel fraction, atmospheric gasoil, and the bottom fraction obtained herein is atmospheric residue.

Then, the atmospheric residue stream is fractionated in a vacuum distillation unit (VDU) to obtain a vacuum distillate and a vacuum residue stream.

The atmospheric residue stream after subjected to a vacuum distillation unit (VDU) leads to the separation of atmospheric residue stream into cycle oils, vacuum gas oil and a vacuum residue stream.

A first predetermined amount of the vacuum residue stream is hydrocracked in a resid hydrocracking unit (RHCU) at a first pre-determined conditions for a first pre-determined time period by using hydrogen gas in the presence of a catalyst to obtain a first product mixture comprising a first distillate, a vacuum gas oil and a gaseous mixture.

In accordance with the embodiments of the present disclosure, the first pre-determined conditions include a temperature in the range of 360 oC to 480 oC, a pressure in the range of 80 bar to 220 bar, an LHSV in the range of 0.1h-1 to 1 h-1.

In accordance with the embodiments of the present disclosure, the first pre-determined time period is in the range of 2 hours to 6 hours. In an exemplary embodiment, the time period is 3 hours.

In accordance with the embodiments of the present disclosure, the first predetermined amount of the vacuum residue stream is in the range of 50 wt% to 100 wt%.

In accordance with the embodiments of the present disclosure, the catalyst is introduced in at least one form selected from the group consisting of colloidal dispersed form, slurry phase dispersed form, extrudate form, water soluble form and oil soluble catalyst form. In an embodiment, the catalyst is introduced in the slurry phase dispersed form.

In accordance with the embodiments of the present disclosure, the catalyst comprises at least one metal selected from the group consisting of molybdenum, iron, nickel, cobalt, and tungsten. In an exemplary embodiment, the metal is molybdenum.

In accordance with the embodiments of the present disclosure, the amount of metal in the catalyst is in the range of 100 ppm to 20,000 ppm. In an exemplary embodiment, the amount is 10,000 ppm.

In accordance with the embodiments of the present disclosure, the volume ratio at normal conditions of hydrogen to the first pre-determined amount of the vacuum residue stream is in the range of 200 to 3000. In an exemplary embodiment, the volume ratio is 800.

In accordance with the embodiments of the present disclosure, the first product mixture further comprises LPG, naphtha, middle distillates, and pitch.
The pitch is highly refractory and hence is not suitable for application as a blending stock for fuels. It can however, in a certain extent be blended with bitumen. As the carbon content of pitch is very high, it can be combusted to produce steam or else gasified to make syngas.

The vacuum gas oil and the gaseous mixture are separated from the first product mixture to obtain a separated gaseous mixture and a separated vacuum gas oil.

In accordance with the embodiments of the present disclosure, the separated vacuum gas oil comprises a portion of the catalyst dispersed therein/within.

In accordance with the embodiments of the present disclosure, the separated gaseous mixture comprises hydrogen in an amount of at least 60 mol%, which is further used in the second hydrocracking unit. In an exemplary embodiment, the amount of hydrogen is 85 mol%.

The separated gaseous mixture comprises at least one alkane selected from the group consisting of methane, ethane, propane and butane.
The separated vacuum gas oil and optionally separated gaseous mixture is mixed with a second predetermined amount of the vacuum residue stream to obtain a resultant mixture.

In an embodiment of the present disclosure, the resultant mixture comprises the separated gaseous mixture comprising hydrogen.

In another embodiment, the resultant mixture does not comprise separated gaseous, and external hydrogen is added to the separated vacuum gas oil and the second predetermined amount of the vacuum residue stream to obtain the resultant mixture.

In accordance with the embodiments of the present disclosure, the second predetermined amount of the vacuum residue stream is in the range of 50 wt% to 80wt%. In an exemplary embodiment, the amount of the vacuum residue stream is 80wt%.

In accordance with the embodiments of the present disclosure, the resultant mixture comprises the separated vacuum gas oil in an amount in the range of 10 wt.% to 40 wt.%. In an exemplary embodiment, the amount is 10 wt.%.

Typically, the vacuum gas oil obtained from the resid hydrocracking unit comprises material having boiling point above 450 oC.

The resultant mixture is hydrocracked in a mild hydrocracking unit (MHC) under a second pre-determined conditions for a second pre-determined time period to obtain a second product mixture comprising a second distillate and the bitumen grade bottom product.

In accordance with the embodiments of the present disclosure, the second pre-determined conditions include a temperature in the range of 350 oC to 450 oC, a total pressure in the range of 1 bar to 80 bar and, an LHSV in the range of 0.5 h-1 to 12 h-1.

In accordance with the embodiments of the present disclosure, the second pre-determined time period is in the range of 5 minutes to 100 minutes. In an exemplary embodiment, the second pre-determined time period is 20 minutes.

In accordance with the embodiments of the present disclosure, a partial pressure of hydrogen in the second hydrocracking unit is in the range of 1 bar to 60 bar. In an exemplary embodiment, the partial pressure is 15 bar.

In accordance with the embodiments of the present disclosure, the hydrocracking in the second hydrocracking unit is carried out without using any additional catalyst.

As the separated vacuum gas oil comprises a portion of the catalyst used in the resid hydrocracking unit dispersed within, no additional catalyst is required to carry out the mild hydrocracking to produce bitumen grade bottom products. Due to efficient recycling of the catalyst dispersed in the separated vacuum gas oil, the overall process becomes efficient and economical.

In accordance with the embodiments of the present disclosure, the mild hydrocracking unit is selected from bubble column and ebullated bed reactor. In an exemplary embodiment, the mild hydrocracking unit is bubble column reactor.
The second product mixture is then fractionated to obtain the bitumen grade bottom products having a penetration value in the range of 35 to 80, a kinematic viscosity in the range of 250 to 400 centistokes, a softening point in the range of 40 oC to 50 oC and a ductility in the range of 25 to 75. In an exemplary embodiment, the bitumen grade bottom products have the penetration value 89, the kinematic viscosity 309.7 centistokes, the softening point 41 oC and the ductility in the range of 55.

In accordance with the embodiments of the present disclosure, the second product mixture comprises the bitumen grade bottom products in an amount in the range of 25 wt% to 65 wt%. In an exemplary embodiment, the amount is 46 wt.%.

In accordance with the embodiments of the present disclosure, the fractionating of the second product mixture provides LPG, naphtha, middle distillates, vacuum gas oil along with bitumen grade bottom products.

In an embodiment of the present disclosure, the process for producing bitumen grade bottom products having a penetration value of 89, a kinematic viscosity in the range of 309.7 centistokes, a softening point in the range of 41 oC and a ductility of 55, the process comprising the following steps:
a) separating a heavy hydrocarbon feed (1) in an atmospheric distillation unit (ADU) (2) to obtain an overhead stream and an atmospheric residue stream;
b) fractionating the atmospheric residue stream in a vacuum distillation unit (VDU) (3) to obtain a vacuum distillate and a vacuum residue stream;
c) hydrocracking a first predetermined amount of the vacuum residue stream in a resid hydrocracking unit (RHCU) (9) at the temperature of 420 oC, the pressure of 120 bar, under the stirring speed of 800 rpm for 3 hours by using hydrogen gas (5) in the presence of the catalyst (6) in the form of slurry dispersed phase and in an amount of 10,000 ppm to obtain a first product mixture comprising a first distillate, a vacuum gas oil and a gaseous mixture;
d) separating the vacuum gas oil and the gaseous mixture from the first product mixture to obtain a separated gaseous mixture and a separated vacuum gas oil;
e) mixing the separated gaseous mixture and the separated vacuum gas oil to a second predetermined amount of the vacuum residue stream to obtain a resultant mixture;
f) hydrocracking the resultant mixture in a mild hydrocracking unit (MHC) (4) at the temperature of 450 oC, the total pressure of 15 bar for 20 minutes time period to obtain a second product mixture comprising a second distillate and the bitumen grade bottom product; and
g) fractionating (7) the second product mixture to obtain the bitumen grade bottom products having a penetration value of 89, a kinematic viscosity in the range of 309.7 centistokes, a softening point in the range of 41 oC and a ductility of 55.
In accordance with the embodiments of the present disclosure, the process can be a continuous process or a batch process.
The present disclosure provides a simple and efficient process for mild hydrocracking of vacuum residue. The process provides mild conditions for hydrocracking by using recovered catalyst and hydrogen from the first hydrocracking unit, thus generating optimum amount of bitumen grade bottom product and middle distillates. Further, the process involves recycling of the catalyst and hydrogen in the second hydrocracking unit, thus making the overall process economical.
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.
EXPERIMENTS DETAILS
Experiment 1: Production of bitumen grade bottom product by hydrocracking of a feed containing Basrah vacuum residue:

475 gram Basrah vacuum residue which contains of 86 wt% of hydrocarbons boiling above 540 °C, was used for this experiment, out of which 250 gram was used during the hydrocracking in resid hydrocracking unit and 225 gram of vacuum residue during the hydrocracking in mild hydrocracking unit.

Hydrocracking in resid hydrocracking unit: Initially, a resid hydrocracking unit, which was a stirred tank reactor, was loaded with 250 gram of Basrah vacuum residue along with a slurry dispersed catalyst. The concentration of the catalyst was 10000 ppm of molybdenum oil soluble catalyst. Then, the resid hydrocracking unit was purged with nitrogen and later was pressurized with Hydrogen at a pressure of 120 bar. Volume ratio of Hydrogen to vacuum residue was 1000. The mixture of the vacuum residue and the catalyst was heated at a temperature of 420 oC under constant stirring of 800 rpm. The hydrocracking reaction was carried out for a period of 3 hour while maintaining the reaction temperature at 420 oC to obtain a first product mixture comprising first distillate, LPG, naphtha, middle distillates and vacuum gas oil and gaseous mixture. The first product mixture was then cooled by circulating chilled water to bring down the temperature of the first product mixture below 30 oC. Gaseous mixture was separated from the first product mixture and then further analyzed using Gas Chromatograph for its composition. The gaseous mixture consisted of 85 mol% (concentration) of hydrogen. Rest of the first product mixture (after separation of gaseous mixture) was collected and analyzed in GC-SIMDIST as per ASTM D-7169. The first distillate, vacuum gas oil, LPG, naphtha, middle distillates were then fractionated in Mini pot still apparatus to separate first distillate, vacuum gas oil, LPG, naphtha, middle distillates, vacuum gas oil from each other. The separated vacuum gas oil comprised the hydrocracking catalyst dispersed therein.

Hydrocracking in mild hydrocracking unit: The mild hydrocracking unit was loaded with 225 gram of Basrah vacuum residue along with 25 gram of vacuum gas oil obtained from the first product mixture having boiling point above 450 oC. Then, the mild hydrocracking unit was purged with nitrogen and later was pressurized with 100 mol% hydrogen at a pressure of 15 bar to obtain a resultant mixture. The hydrocracking severity in the mild hydrocracking unit was milder with milder conditions and without addition of any external catalyst. The resultant mixture was heated to 420 oC and the hydrocracking was carried out for a period of 20 minutes while maintaining the temperature at 420 oC to obtain a second product mixture. The second product mixture comprising LPG, naptha, middle distillates and bitumen grade material was cooled by circulating chilled water to bring down the temperature below 30 oC. The gaseous products were analyzed using Gas Chromatograph for its composition. The liquid sample was collected and analyzed in GC-SIMDIST as per ASTM D-7169. The products were fractioned in minipotstill apparatus to get the individual fractions. The bottom product cut having boiling point above 540 oC was further characterized for bitumen properties.
Table 1: Composition of second product mixture
vacuum residue Results according to example-1
Yields (Wt%)
Gas 3.1
LPG 1.0
Naphtha (<180 oC) 5.6
Distillates (180-370 oC) 14.5
VGO (370-540 oC) 14 29.9
Unconverted residue (540 oC+), 86 45.8
(Bitumen grade bottom product)
Conversion % 54.2

Table 1 represents the results for distillates and bitumen range bottom product obtained after the hydrocracking process in resid hydrocracking unit. The results represent the distillate yields of ~ 50% for naphtha, middle distillates and VGO and bitumen material yield of ~46% with conversion of 54.2%.
Table 2: Properties of Bitumen grade material.
Property Vacuum residue Bottom product after second hydrocracking process as per example
Penetration at 25degC, Min 27 89
Kinematic Viscosity, cSt, Min 428.8 309.7
Softening Point, DegC, Min 47 41
Ductility, Min - 55

Table 2 shows characterization of bitumen grade bottom product for the properties such as softening point, ductility, penetration point and kinematic viscosity. The results show that the material properties are in close matching with the viscosity grade bitumen.

It is further to be observed upon blending with lighter fractions, the properties of bitumen can be varied between viscosity grade 10 – viscosity grade 40 grade bitumen specifications.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of an integrated process for hydrocracking of vacuum residue that:
? is simple, efficient and economical; and
? provides hydrocracked products with optimum amount of bitumen grade bottom product middle distillates.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
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 invention to achieve one or more of the desired objects or results. While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Variations or modifications to the formulation of this invention, within the scope of the invention, may occur to those skilled in the art upon reviewing the disclosure herein. Such variations or modifications are well within the spirit of this invention.
The numerical values given for various physical parameters, dimensions, and quantities are only approximate values, and it is envisaged that the values higher than the numerical value assigned to the physical parameters, dimensions, and quantities fall within the scope of the invention unless there is a statement in the specification to the contrary.
While considerable emphasis has been placed herein on the specific features of the preferred embodiment, it will be appreciated that many additional features can be added and that many changes can be made in the preferred embodiment without departing from the principles of the disclosure. These and other changes in the preferred embodiment 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. An integrated vacuum residue hydrocracking process for producing bitumen grade bottom products having a penetration value in the range of 35 to 80, a kinematic viscosity in the range of 250 to 400 centistokes, a softening point in the range of 40 oC to 50 oC and a ductility in the range of 25 to 75, said process comprising the following steps:
a) obtaining a vacuum residue stream;
b) hydrocracking a first predetermined amount of said vacuum residue stream in a resid hydrocracking unit (RHCU) at a first pre-determined conditions for a first pre-determined time period by using hydrogen gas in the presence of a catalyst to obtain a first product mixture comprising a first distillate, a vacuum gas oil and a gaseous mixture;
c) separating said vacuum gas oil and said gaseous mixture from said first product mixture to obtain a separated gaseous mixture and a separated vacuum gas oil;
d) mixing said separated vacuum gas oil and optionally separated gaseous mixture to a second predetermined amount of said vacuum residue stream to obtain a resultant mixture;
e) hydrocracking said resultant mixture in a mild hydrocracking unit (MHC) under a second pre-determined conditions for a second pre-determined time period to obtain a second product mixture comprising a second distillate and said bitumen grade bottom product; and
f) fractionating said second product mixture to obtain said bitumen grade bottom products.

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

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

4. The process as claimed in claim 1, wherein said first pre-determined time period is in the range of 2 hours to 6 hours.

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

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

7. The process as claimed in claim 1, wherein said 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 as claimed in claim 1, wherein said catalyst comprises at least one metal selected from the group consisting of molybdenum, iron, nickel, cobalt, and tungsten.

9. The process as claimed in claim 8, wherein the amount of metal in said catalyst is in the range of 100 ppm to 20,000 ppm.

10. The process as claimed in claim 1, wherein the weight ratio of hydrogen to said first pre-determined amount of said vacuum residue stream is in the range of 200 to 3000.

11. The process as claimed in claim 1, wherein said first product mixture further comprises LPG, naphtha, middle distillates, and pitch.

12. The process as claimed in claim 1, wherein said separated gaseous mixture comprises hydrogen in an amount of at least 60 mol%, which is further used in said second hydrocracking unit.

13. The process as claimed in claim 1, wherein said resultant mixture comprises said separated vacuum gas oil in an amount in the range of 10 wt.% to 40 wt.%.

14. The process as claimed in claim 1, wherein said separated vacuum gas oil comprises a portion of said catalyst dispersed therein/within.

15. The process as claimed in claim 1, wherein second pre-determined conditions include a temperature in the range of 350 oC to 450 oC, a total pressure in the range of 1 bar to 80 bar and, an LHSV in the range of 0.5 h-1 to 12 h-1.

16. The process as claimed in claim 1, wherein said second pre-determined time period is in the range of 5 minutes to 100 minutes.

17. The process as claimed in claim 1, wherein a partial pressure of hydrogen in said second hydrocracking unit is in the range of 1 bar to 60 bar.

18. The process as claimed in claim 1, wherein said hydrocracking in said second hydrocracking unit is carried out without using any additional catalyst.

19. The process as claimed in claim 1, wherein said second product mixture comprises said bitumen grade bottom product in an amount in the range of 25 wt% to 65 wt%.

20. The process as claimed in claim 1, said fractionating of said second product mixture provides LPG, naphtha, middle distillates, vacuum gas oil along with bitumen grade bottom products.

21. The process as claimed in claim 1, wherein said resid hydrocracking unit is selected from bubble column reactors and ebullated bed reactors.
Dated this 4th Day of July, 2020

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