Abstract: Systems and methods for hydroprocessing a heavy oil feedstock are disclosed. The system employs a plurality of contacting zones and at least one separation zone, wherein a solvating hydrocarbon having a normal boiling point less than 538° C. (1000° F.) is employed. In the system, a mixture of heavy oil feedstock and solvating hydrocarbon is provided to a contact zone along with a slurry catalyst feed in a hydrocarbon diluent. The contacting zone operates at a temperature and pressure near the critical temperature and pressure of the heavy oil and solvating hydrocarbon mixture to convert at least a portion of the heavy oil feedstock to lower boiling hydrocarbons, forming upgraded products.

Abstract: Systems and methods for hydroprocessing a heavy oil feedstock are disclosed. The system employs a plurality of contacting zones and at least one separation zone, wherein a solvating hydrocarbon having a normal boiling point less than 538° C. (1000° F.) is employed. In the system, a mixture of heavy oil feedstock and solvating hydrocarbon is provided to a contact zone along with a slurry catalyst feed in a hydrocarbon diluent. The contacting zone operates at a temperature and pressure near the critical temperature and pressure of the heavy oil and solvating hydrocarbon mixture to convert at least a portion of the heavy oil feedstock to lower boiling hydrocarbons, forming upgraded products.

Abstract: A process and system which integrates on-site heavy oil or bitumen upgrading and energy recovery for steam production with steam-assisted gravity drainage (SAGD) production of the heavy oil or bitumen. The heavy oil or bitumen produced by SAGD is flashed to remove the gas oil fraction, and the residue is solvent deasphalted to obtain deasphalted oil, which is mixed with the gas oil fraction to form a pumpable synthetic crude. The synthetic crude has an improvement of 4-5 degrees of API and lower in sulfur, nitrogen and metal compounds. The synthetic crude is not only more valuable than the heavy oil or bitumen, but also has substantial economic advantage of reducing the diluent requirement since it has lower viscosity than the heavy oil or bitumen. The asphaltenes, following an optional pelletizing and/or slurrying step, are used as a fuel for combustion in boilers near the steam injection wells for injection into the heavy oil or bitumen reservoir.

Abstract: The invention is a process for making anode grade coke which comprises solvent deasphalting a residue feedstock to obtain an essentially asphaltene-free, resin-containing stream and coking the resin-containing stream in a delayed coker to make anode coke. The solvent deasphalting can make a deasphalted oil stream containing resin or separate deasphalted oil and resin streams. There can be hydrotreating of (1) a minor portion of the residue feedstock wherein the hydrotreated residue is fed to the delayed coker with the resin-containing stream, (2) the resin-containing stream wherein the hydrotreated resin stream is fed to the delayed coker, or (3) a major portion of the residue feedstock wherein the hydrotreated residue is fed to the solvent deasphalting unit.