PRODUCTION

FIELD

[0001] Systems and methods are provided for production of lubricant oil base stocks using a processing train in blocked operation. The systems and methods allow for production of Group II and Group III lubricant base stocks from a feed.

BACKGROUND

[0002] Lubricant base stocks are one of the higher value products that can be generated from a crude oil or crude oil fraction. The ability to generate lubricant base stocks of a desired quality is often constrained by the availability of a suitable feedstock. For example, most conventional processes for lubricant base stock production involve starting with a crude fraction that has not been previously processed under severe conditions, such as a virgin gas oil fraction from a crude with moderate to low levels of initial sulfur content.

[0003] A number of challenges in production of lubricant base stocks are related to the competing desires of generating as high a yield of base stocks as possible while also meeting target specifications for multiple types of base stocks. For example, it can be desirable to produce both light neutral and medium / heavy neutral grades of lubricant base stocks from a single feed. Unfortunately, the processing conditions required for meeting the product specifications for a light neutral lubricant base stock are often substantially higher in severity than the processing conditions for meeting the product specifications for a medium neutral or heavy neutral base stock. Processing the feed at the higher severity conditions can lead to additional feed conversion, resulting in overall loss in lubricant yield.

[0004] U.S. Patent Application Publication 2011/0315596 describes an integrated process for hydrocracking and dewaxing of hydrocarbons to form naphtha, diesel, and/or lubricant base stock boiling range products. The integrated process includes dewaxing and optionally hydrocracking under sour conditions, a separation to form a first diesel product and a bottoms product, and additional hydrocracking and dewaxing to form a second diesel product and optionally a lubricant base oil product. The hydrocracking and dewaxing catalysts can include base metals or can include Pd and/or Pt. An example of a hydrocracking catalyst is USY and an example of a dewaxing catalyst is ZSM-48.

[0005] U.S. Patent 8,932,454 describes a method of making and using a Y zeolite hydrocracking catalyst. The Y zeolite catalyst has a small mesoporous peak in the pore size distribution of around 40 A as measured by nitrogen desorption. [0006] U.S. Patent 8,778, 171 describes a method of making and using a Y zeolite hydrocracking catalyst. The Y zeolite catalyst contains stabilized aggregates of Y zeolite primary crystallites having a size of 0.5 microns or less.

[0007] U.S. Patent Application Publication 2013/0341243 describes a hydrocracking process selective for improved distillate and improved lube yield and properties. A two-stage hydrocracking catalyst can be used for hydrocracking of a feed to form a converted portion suitable for diesel fuel production and an unconverted portion suitable for production of lubricant base stocks. The two-stage hydrocracking catalyst can correspond to a first stage catalyst including Pd and/or Pt supported on USY and a second stage catalyst including Pd and/or Pt supported on ZSM- 48.

SUMMARY

[0008] In various aspects, methods are provided for producing lubricant boiling range product using blocked operation. The methods can include fractionating a hydroprocessed feedstock to form at least a first lubricant boiling range fraction comprising a 343°C+ portion and a second lubricant boiling range fraction having a T10 distillation point of at least 343°C and a kinematic viscosity at 100°C of 6.0 cSt or more. The 343°C+ portion of the first lubricant boiling range fraction can have a kinematic viscosity at 100°C of 1.5 cSt to 6.0 cSt. The second lubricant boiling range fraction can optionally have a viscosity index that is greater than the viscosity index of the first lubricant boiling range fraction. The first lubricant boiling range fraction and the second lubricant boiling range fraction can be processed based on block operation of a reaction system. For example, At least a portion of the first lubricant boiling range fraction can be hydrocracked in the presence of hydrocracking catalyst under first hydrocracking conditions in a first reactor to form a first hydrocracked effluent. The first hydrocracking conditions can include a first hydrocracking inlet temperature and a first hydrocracking outlet temperature. The first hydrocracking conditions can correspond to conditions for 10 wt% to 80 wt% conversion relative to 370°C of the at least a portion of the first lubricant boiling range fraction. At least a portion of the first hydrocracked effluent can be dewaxed under first catalytic dewaxing conditions in a second reactor to form a first dewaxed effluent. The second lubricant boiling range product can also be hydrocracked, but under second hydrocracking conditions. The second hydrocracking conditions can include 1 wt% to 25 wt% conversion relative to 370°C of the at least a portion of the second lubricant boiling range fraction, along with a second hydrocracking inlet temperature and a second hydrocracking outlet temperature. The conversion relative to 370°C for the first hydrocracking conditions can be at least 10 wt% greater than the conversion relative to 370°C for the second hydrocracking conditions. At least a portion of the second hydrocracked effluent can be dewaxed under second catalytic dewaxing conditions in the second reactor to form a second dewaxed effluent. At least a portion of the first dewaxed effluent can be fractionated to form at least a first fuels boiling range product and a first lubricant boiling range product. Similarly, at least a portion of the second dewaxed effluent can be fractionated to form at least a second fuels boiling range product and a second lubricant boiling range product. A viscosity index of the second lubricant boiling range product can being lower than a viscosity index of the first lubricant boiling range product by at least 5.

[0009] In some aspects, the hydroprocessed feedstock can be formed by hydroprocessing a feedstock under hydroprocessing conditions. Optionally, instead of fractionating the hydroprocessed feedstock, block processing can also be used for the initial hydroprocessing of the feedstock. In such aspects, an initial feedstock can be fractionated to form at least a first lubricant boiling range fraction comprising a 343°C+ portion and a second lubricant boiling range fraction having a T10 distillation point of at least 343°C and a kinematic viscosity at 100°C of 6.0 cSt or more, the 343°C+ portion having a kinematic viscosity at 100°C of 1.5 cSt to 6.0 cSt. In this type of aspect, the first lubricant boiling range fraction and the second lubricant boiling range fraction can be processed separately to form hydroprocessed lubricant boiling range fractions for subsequent hydrocracking and dewaxing.

[0010] In some aspects, the second catalytic dewaxing conditions can include a second dewaxing inlet temperature that is greater than the second hydrocracking outlet temperature, while the first catalytic dewaxing conditions can include a first dewaxing inlet temperature that is less than the first hydrocracking outlet temperature. This type of control over the dewaxing inlet temperature can be facilitated, for example, by introducing a heated hydrogen-containing stream into the second reactor during the second catalytic dewaxing conditions.

[0011] In some aspects, the block processing of the feeds can be facilitated by storing the at least a portion of the first lubricant boiling range fraction prior to the hydrocracking of the at least a portion of the first lubricant boiling range fraction, ii) further comprising storing the at least a portion of the second lubricant boiling range fraction prior to the hydrocracking of the at least a portion of the second lubricant boiling range fraction, or iii) a combination of i) and ii).

[0012] In some aspects, the first reactor can further include an aromatic saturation catalyst, and/or the second reactor further can further include an aromatic saturation catalyst.

[0013] In some aspects, the first lubricant boiling range product can have a viscosity index of at least 125. Additionally or alternately, the second lubricant boiling range product can have a viscosity index of at least 80. Additionally or alternately, the viscosity index of the second lubricant boiling range product can be lower than the viscosity index of the first lubricant boiling range product by at least 15.

[0014] In some aspects, the first dewaxing conditions can besubstantially similar to the second dewaxing conditions. In some aspects, the first hydrocracking inlet temperature can be greater than the second hydrocracking inlet temperature by at least 10°C.

[0015] Optionally, the method can further include exposing at least a portion of the first dewaxed effluent to an aromatic saturation catalyst in a third reactor under first aromatic saturation conditions to form a first saturated product comprising the first lubricant boiling range product. In such aspects, the first lubricant boiling range product can have an aromatics content of 2.0 wt% or less. Optionally, the method can also further include exposing at least a portion of the second dewaxed effluent to the aromatic saturation catalyst in the third reactor under second aromatic saturation conditions to form a second saturated product comprising the second lubricant boiling range product. The second lubricant boiling range product can have an aromatics content of 2.0 wt% or less. The first aromatic saturation conditions can optionally be substantially similar to the second aromatic saturation conditions. The second reactor can optionally further comprise a second aromatic saturation catalyst, the at least a portion of the first hydrocracked effluent contacting at least a portion of the second aromatic saturation catalyst prior to being exposed to the dewaxing catalyst.

[0016] In various aspects, a multi-reactor reaction system is provided. The multi-reactor reaction system can include a first reactor comprising a first gas inlet, a hydrocracking reactor inlet, and a hydrocracking reactor outlet. The first reactor can also include a hydrocracking catalyst comprising 0.1 wt% to 5.0 wt% of a Group 8 - 10 noble metal supported on the hydrocracking catalyst. The system can further include a second reactor comprising a second gas inlet, a dewaxing reactor inlet, and a dewaxing reactor outlet. The second reactor can further include a dewaxing catalyst. The dewaxing reactor inlet can be in fluid communication with the hydrocracking reactor outlet. The system can further include a third reactor comprising an aromatic saturation inlet, an aromatic saturation outlet, and a first aromatic saturation catalyst. The aromatic saturation inlet can be in fluid communication with the dewaxing reactor outlet. The system can further include a heater having a feed heater flow path and a hydrogen heater flow path. The feed heater flow path can be in fluid communication with the hydrocracking reactor inlet. The hydrogen heater flow path can be in fluid communication with the first gas inlet and the second gas inlet. Optionally, at least a portion of a second aromatic saturation catalyst can be located upstream from the dewaxing catalyst relative to a direction of flow in the second reactor. Optionally, the system can further include a third reactor that includes a third gas inlet in fluid communication with the hydrogen heater flow path.

[0017] In some aspects, the hydrocracking reactor inlet can correspond to the first gas inlet. In some aspects, the second gas inlet can be in selective fluid communication with the heated hydrogen flow path.

[0018] Optionally, the system can further include a first storage tank and a second storage tank, the first storage tank and the second storage tank can be in selective fluid communication with the feed heater flow path. The first storage tank can store the first lubricant boiling range feed and the second storage tank can store the second lubricant boiling range feed.

[0019] In various aspects, a method for producing a lubricant boiling range product is provided. The method can include hydrocracking a lubricant boiling range fraction in the presence of hydrocracking catalyst under first hydrocracking conditions in a first reactor to form a first hydrocracked effluent. The first hydrocracking conditions can correspond to a first amount of conversion relative to 370°C of the lubricant boiling range fraction. At least a portion of the first hydrocracked effluent can be dewaxed under first catalytic dewaxing conditions in a second reactor to form a first dewaxed effluent. The first dewaxing inlet temperature can be greater than the first hydrocracking outlet temperature by at least 3°C. The conditions for hydrocracking can then be modified while performing hydrocracking of the lubricant boiling range fraction. The lubricant boiling range fraction can be hydrocracked under the modified hydrocracking conditions in the first reactor to form a second hydrocracked effluent. The modified hydrocracking conditions can correspond to a second amount of conversion relative to 370°C of the lubricant boiling range fraction that is different from the first amount of conversion relative to 370°C by 5 wt% or less. At least a portion of the second hydrocracked effluent can be dewaxed under second catalytic dewaxing conditions in the second reactor to form a second dewaxed effluent. The second dewaxing inlet temperature can be less than the modified hydrocracking outlet temperature by at least 3°C. The resulting first dewaxed effluent and second dewaxed effluent can be fractionated to form (optional) fuels boiling range products and lubricant boiling range products. Optionally, the dewaxed effluents can be hydrofinished before and/or after fractionation to form the lubricant boiling range products. A viscosity index of the second lubricant boiling range product can be different than a viscosity index of the first lubricant boiling range product by 5 or less.

[0020] The lubricant boiling range fraction can correspond to a feedstock suitable for forming any convenient type of lubricant fraction. For example, the lubricant boiling range fraction can correspond to a feed for heavy neutral base stock production, such as a feed having a T10 distillation point of at least 343°C and a kinematic viscosity at 100°C of 6.0 cSt or more; or a feed for brightstock production, such as a feed having a T10 distillation point of at least 371°C and a kinematic viscosity at 100°C of 15 cSt or more; or a feed for light neutral base stock production, such as a feed having a 343°C+ portion, the 343°C+ portion having a kinematic viscosity at 100°C of 1.5 cSt to 6.0 cSt.

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] FIG. 1 schematically shows an example of a configuration suitable for processing a feedstock to form at least a lubricant boiling range fraction.

[0022] FIG. 2 schematically shows another example of a configuration suitable for processing a feedstock to form at least a lubricant boiling range fraction.

[0023] FIG. 3 schematically shows another example of a configuration suitable for processing a feedstock.

[0024] FIG. 4 schematically shows an example of a reaction system including multiple reactors and multiples heated hydrogen lines.

DETAILED DESCRIPTION

Overview

[0025] All numerical values within the detailed description and the claims herein are modified by "about" or "approximately" the indicated value, and take into account experimental error and variations that would be expected by a person having ordinary skill in the art.

[0026] In various aspects, systems and methods are provided for block processing of a feedstock to produce multiple viscosity grades of lubricant base stocks with substantially different viscosity index values. The systems and methods can involve the use of a sweet stage hydrocracking catalyst that can maintain good aromatic saturation activity under conditions that produce substantially different levels of viscosity index uplift. Optionally, the reactor including the sweet stage hydrocracking catalyst can include additional aromatic saturation catalyst. The systems and methods can further involve using a combination of aromatic saturation catalyst and dewaxing catalyst in a second sweet stage reactor, so that additional aromatic saturation activity is available for saturation of aromatics for products that undergo lower amounts of conversion in the sweet hydrocracking stage.

[0027] The systems and methods described herein can allow a single reaction system, operated in a block processing mode, to start with a single feedstock and generate a light neutral and a heavy neutral product with a viscosity index difference of at least 25, or at least 30, or at least 40, while also maintaining the aromatics content of both the light neutral and the heavy neutral products at 2.0 wt% or less, or 1.0 wt% or less. Using a traditional sweet stage hydrocracking catalyst and/or using a traditional sweet stage dewaxing reactor without substantial initial aromatic saturation activity, achieving this desirable combination of features (high VI difference, low aromatics content) in a light neutral and a heavy neutral product derived from a single feedstock would require separate processing trains.

[0028] The block processing can be further facilitated based on use of separate hot hydrogen lines for introducing heated hydrogen into two or more of the sweet stage reactors. A sweet stage can often include a plurality of reactors, such as a hydrocracking reactor, a dewaxing reactor, and a hydrofinishing reactor. It can be desirable to set the temperature of each reactor at different levels in order to provide improved control over processing conditions. In various aspects, additional control over processing conditions can be provided based on the use of heated hydrogen lines that are introduced into subsequent reactor(s) in the sweet hydroprocessing stage. Instead of adding heat primarily in the initial reactor and/or by heat exchange on the effluents from the reactors, the use of heated hydrogen lines can allow for additional control over the temperature of the input flows to subsequent reactor stages.

[0029] As an example, use of heated hydrogen lines can allow the sweet stage reactor train to be used for processing one feed (such as a feed for light neutral production) during block operation with the hydrocracking (first) reactor operated at a higher outlet temperature than the inlet temperature of the dewaxing (second) reactor. By using a heated hydrogen line to deliver heated hydrogen to the second reactor during processing of a feed for heavy neutral production, the same sweet stage reactor train can be operated to have a hydrocracking reactor outlet temperature that is colder than the dewaxing reactor inlet temperature. During such heavy neutral production, the outlet temperature of the hydrocracking reactor can be cooler than the inlet temperature of the dewaxing reactor by at least 10°C, or at least 20°C, or at least 30°C. This can allow a single sweet stage reactor train to be used for block processing while reducing or minimizing the yield loss due to over-cracking of the feed for heavy neutral production.

[0030] In addition to facilitating block processing, additional control over the inlet and outlet temperatures for reactors in a reactor configuration can also allow for switching of the relative temperature profiles for reactors during processing of a single feed. For example, in sweet processing stage for lubricant production, separate reactors can be used for hydrocracking and dewaxing of the feed. As noted above, the temperature of the first reactor is typically selected to provide the desired temperature for the highest temperature stage in the reaction system. By allowing for increased control over the temperature of reactors, the reactor corresponding to the "warmest" reactor can be changed during processing of a feed. As an example, during processing of a heavy neutral feed, a relatively low temperature may be sufficient for the hydrocracking stage, as the amount of viscosity index uplift required for a heavy neutral is often small. As a result, the outlet temperature for the hydrocracking reactor can be lower than the desired inlet temperature for dewaxing. However, as processing continues and the catalyst is aged, increasingly higher temperatures may be needed to maintain a desired level of viscosity index uplift. Based on this catalyst aging, the temperature (and/or other conditions associated with hydrocracking) can be modified during processing of the feed, in order to maintain the properties of the resulting lubricant product in a desired range. This can eventually result in having a higher outlet temperature for the hydrocracking reactor than the inlet temperature for the dewaxing reactor. For example, the temperature of the hydrocracking conditions can be modified so that at a later point during processing, the viscosity index of the lubricant boiling range product differs from the viscosity index of the product at an earlier time by less than 5, or less than 3, or possibly even less than 1. In some aspects, aging of the dewaxing catalyst may also occur. Modifying the temperature (and/or other conditions) of the dewaxing process may also be used to maintain a desired pour point for the resulting lubricant product. For example, the temperature of the dewaxing conditions can be modified so that at a later point during procsssing, the pour point of the lubricant boiling range product differs from the pour point of the product at an earlier time by less than 10°C, or less than 6°C, or less than 3°C.

[0031] More generally, changing of the "warmest" reactor in a reactor sequence can be used during processing of any convenient type of lubricant feed, including feeds for production of light neutral base stocks (1.5 cSt to 6.0 cSt at 100°C), feeds for production of heavy neutral base stocks (6.0 cSt to 12 cSt at 100°C, or 6.0 cSt to 15 cSt, or 6.0 cSt to 20 cSt), or feeds for production of brightstock (15 cSt or more, or 20 cSt or more, or 25 cSt or more, or 30 cSt or more, such as up to 50 cSt or possibly still higher). The heated hydrogen lines described herein can facilitate having this type of switch in the relative temperatures of the reactors. In various aspects, the outlet temperature of the hydrocracking reactor at an initial point in a processing run can be lower than the inlet temperature of the dewaxing reactor, or at least 3°C lower, or at least 5°C lower, or at least 8°C lower, or at least 10°C lower. At a later point in the processing run, the outlet temperature of the hydrocracking reactor can be higher than the inlet temperature for the dewaxing reactor, or at least 3°C higher, or at least 5°C higher, or at least 8°C higher, or at least 10°C higher.

[0032] During processing of a feedstock for lubricant base stock production, a two stage reaction system can be used. The first stage can correspond to a sour processing stage to reduce the sulfur content, nitrogen content, and/or content of other heteroatoms in the feedstock to a desired level. The first (sour) processing stage can be a stage where the entire feedstock is processed. Alternatively, if it is desired, the first processing stage can be operated in block processing mode. If the first (sour) processing stage is operated in block processing mode, a separation can be performed on the feedstock to produce a first fraction that includes the feed for the desired light neutral product and a second fraction that includes the feed for the desired heavy neutral product. It is noted that due to conversion, some additional light neutral product may be made during processing of the second fraction. Optionally, at least a portion of this additional light neutral product can be separated from the heavy neutral product and added to the light neutral fraction. In other aspects, any light neutral product made during conversion of the feed for heavy neutral production can be retained with the heavy neutral product. Based on the substantially lower viscosity index of the heavy neutral product, it may not be desirable to separate a portion of the lower viscosity index product for combination with the higher viscosity index light neutral product.

[0033] When selecting conditions for hydrotreating and/or hydrocracking in the first stage, the conditions can be selected to achieve two goals. First, the heteroatom content of the feed can be reduced to a desired amount, as noted above. Second, the severity of the first stage conditions can be selected to provide a desired amount of feed conversion, such as conversion relative to 370°C, so that the 343°C+ portion of the first stage effluent has a desired viscosity index. Depending on the aspect, the 343°C+ portion of the first stage effluent can have a viscosity index of 70 - 90. Additionally or alternately, after fractionation of the first stage effluent to form feeds for blocked operation in the second stage, the 343°C+ portion of the feed to the second stage for production of a light neutral fraction can have a viscosity index of 65 - 90 while the feed to the second stage for production of a heavy neutral fraction can have a viscosity index of 70 - 90, or 75 - 95. In various aspects, the viscosity index of the feed to the second stage for production of a heavy neutral can have a viscosity index that is at least 3 greater than the corresponding feed for production of a light neutral, or at least 5 greater, or at least 8 greater, such as up to 15 greater or more. In optional aspects where the first stage feed is blocked, the feed for light neutral production and the feed for heavy neutral production can be processed separately in the first stage and in the second stage. In such optional aspects, the viscosity index of the feed to the first stage for light neutral production and/or the viscosity index of the feed to the first stage for heavy neutral production can be 10 to 70 (or possibly higher, such as 10 to 90).

[0034] During blocked operation of the second stage, the amount of conversion for each feed can be selected to achieve a desired amount of viscosity index uplift. For a feed for light neutral base stock production, the amount of conversion relative to 370°C can be 10 wt% to 80 wt%, or 40 wt% to 80 wt%, or 20 wt% to 60 wt%, or 40 wt% to 70 wt%. This amount of conversion can allow for production (after final fractionation) of a light neutral base stock product having a kinematic viscosity at 100°C of 1.5 cSt to 6.0 cSt, or 2.0 cSt to 6.0 cSt or more, or 2.0 cSt to 5.0 cSt, or 1.5 cSt to 4.0 cSt or more. The light neutral base stock product can have a viscosity index of 120 - 140, or 125 - 145, or 130 - 150. For a feed for heavy neutral base stock production, the amount of conversion relative to 370°C can be 1 wt% to 25 wt%, or 5 wt% to 25 wt%, or 1 wt% to 20 wt%. This amount of conversion can allow for production (after final fractionation) of a heavy neutral base stock product having a kinematic viscosity at 100°C of 6.0 cSt or more, or 6.5 cSt or more, or 8.0 cSt or more, such as up to 16 cSt or possibly still higher. The heavy neutral base stock product can have a viscosity index of 80 - 100, or 80 - 95, or 85 - 100. In various aspects, the viscosity index of the light neutral base stock product can be at least 5 greater than the corresponding heavy neutral base stock product, or at least 15 greater, or at least 25 greater, or at least 35 greater, such as up to 50 greater or more. Additionally, the amount of conversion for the feed for light neutral production can be at least 10 wt% greater than the amount of conversion for the feed for heavy neutral production, or at least 15 wt% greater, or at least 20 wt% greater.

[0035] In order to achieve a desired difference in the conversion amounts, the inlet temperature for hydrocracking for the feed for light neutral production can be at least 10°C higher than the inlet temperature for hydrocracking for the feed for heavy neutral production, or at least 15°C higher, or at least 20°C higher, such as up to 40°C higher or possibly still more. Optionally, the relatively temperatures of the reactors within the second stage can be changed due to the differences in hydrocracking inlet temperatures. For example, the hydrocracking inlet temperature for production of a light neutral base stock can typically be greater than the dewaxing inlet temperature. However, based on the ability to independently heat subsequent reactors, the hydrocracking inlet temperature for production of a heavy neutral base stock can optionally be colder than the dewaxing inlet temperature. Depending on the aspect, the dewaxing inlet temperature can be 1°C or more higher than the hydrocracking exit temperature, or 10°C or more greater, or 20°C or more greater, or 30°C or more greater, such as up to 45°C greater (or possibly a still larger difference).

[0036] Greater flexibility can be available when selecting conditions for hydrotreating and/or hydrocracking during blocked operation of both the first stage and the second stage. The amount of conversion in the first stage can still be sufficient to reduce the heteroatom content of the feed can be reduced to a desired amount, so that the second stage can be operated under sweet conditions. However, higher amounts of conversion than necessary for heteroatom removal could be selected in the first stage. So long as the second stage is processed under sweet conditions and the target viscosity and viscosity index are achieved, any convenient balance of conversion between the first and second stages can be used for each feed that is block processed. For example, in some aspects it may be convenient to reduce the first stage conversion for a feed for heavy neutral production to the minimum value for heteroatom removal. This can allow additional conversion to be performed in the second stage, which may simplify selection of temperatures for the various reactors in the second stage. Similarly, performing additional conversion in the first stage for processing a feed for light neutral production may be beneficial to reduce the conversion requirements in the second stage. The availability of heated hydrogen lines to subsequent reactors in the first stage and/or the second stage can allow for flexibility in selecting temperatures for the reactors in the second stage, so that the link between the inlet temperature for conversion reactors and the inlet temperature of other reactors can be reduced or minimized.

[0037] During blocked operation of both the first stage and the second stage, the amount of conversion for each feed can be selected to achieve a desired amount of viscosity index uplift. For a feed for light neutral base stock production, the combined amount of conversion relative to 370°C across both the sour stage and the sweet stage can be 40 wt% to 80 wt%, or 50 wt% to 80 wt%, or 40 wt% to 70 wt%. This amount of conversion can allow for production (after final fractionation) of a light neutral base stock product having a kinematic viscosity at 100°C of 1.5 cSt to 6.0 cSt, or 2.0 cSt to 6.0 cSt or more, or 2.0 cSt to 5.0 cSt, or 1.5 cSt to 4.0 cSt or more. The light neutral base stock product can have a viscosity index of 120 - 140, or 125 - 145, or 130 - 150. For a feed for heavy neutral base stock production, the combined amount of conversion relative to 370°C across both the sour stage and the sweet stage can be 20 wt% to 60 wt%, or 30 wt% to 50 wt%, or 20 wt% to 40 wt%. This amount of conversion can allow for production (after final fractionation) of a heavy neutral base stock product having a kinematic viscosity at 100°C of 6.0 cSt or more, or 6.5 cSt or more, or 8.0 cSt or more, such as up to 16 cSt or possibly still higher. The heavy neutral base stock product can have a viscosity index of 80 - 100, or 80 - 95, or 85 - 100. In various aspects, the viscosity index of the light neutral base stock product can be at least 5 greater than the corresponding heavy neutral base stock product, or at least 15 greater, or at least 25 greater, or at least 35 greater, such as up to 50 greater or more. Additionally, the combined amount of conversion across both the sour stage and the sweet stage for the feed for light neutral production can be at least 10 wt% greater than the combined amount of conversion for the feed for heavy neutral production, or at least 15 wt% greater, or at least 20 wt% greater.

[0038] Conventionally, some difficulties in attempting to select process conditions during block processing of lubricant feeds can be related to the competing goals of achieving a desired viscosity index for a light neutral base stock while achieving one or more desired cold flow properties for a heavy neutral base stock. For light neutral base stock production, it can be beneficial to perform hydrocracking at relatively higher temperatures, in order to provide increased conversion and therefore increased viscosity index uplift. Based on the relatively higher temperature in the hydrocracking reactor, the effluent from hydrocracking can be at a temperature to allow for dewaxing to achieve desired cold flow properties. By contrast, the viscosity index of a feed for heavy neutral base stock production can often require little or no additional viscosity index uplift in order to meet a desired product viscosity index. Therefore, it would be desirable to pass the feed for heavy neutral production through the hydrocracking reactor at a relatively lower temperature, in order to reduce or minimize yield loss that can occur during hydrocracking. However, this can result in a colder exit temperature from the hydrocracking reactor. This colder exit temperature may not be sufficient in the dewaxing reactor to achieve desired cold flow properties in the dewaxing reactor.

[0039] In a conventional reaction system configuration, the primary method of controlling the temperature of a stage of a reaction system can be based on passing the feed through a heater prior to having the feed enter the initial reactor of the stage. In this type of conventional configuration, the use of a single feed heater prior to the first reactor results in a linkage between the inlet temperature of the initial reactor, such as a hydrocracking reactor, and the inlet temperature of the second reactor, such as a dewaxing reactor. Some modification of the link between the hydrocracking inlet temperature and the dewaxing inlet temperature can be provided by using conventional cooling or quench streams. However, such quench streams are typically only suitable for cooling an effluent prior to entering the next reactor. In a situation where it is desirable to perform little or no hydrocracking on a feed for heavy neutral production, but where a sufficiently high temperature is needed to perform dewaxing, the conventional solution is to perform hydrocracking at a higher temperature than needed for viscosity index uplift. This results in some yield loss, but provides the necessary input temperature for dewaxing. This loss of yield can be avoided by using hot hydrogen lines as described herein, as use of the hot hydrogen lines can allow for greater variation between the inlet temperature of the hydrocracking reactor and the inlet temperature of a subsequent dewaxing reactor.

[0040] Additionally or alternately, operating the second stage at a low amount of conversion can potentially lead to reduced aromatic saturation in the hydrocracking reactor of the second stage. In order to maintain the aromatics in the final heavy neutral lubricant product at a desired level, an additional bed of aromatic saturation catalyst can be included as an initial catalyst bed (or beds) in the dewaxing reactor. This can provide additional aromatic saturation activity for aspects where the exit temperature of the hydrocracking reactor is colder than the target inlet temperature of the dewaxing reactor.

[0041] When fractionating a feed prior to hydroprocessing for blocked operation and/or fractionating the hydroprocessed effluent from the first stage to form the feeds for blocked operation of the second stage, the fractionation can be performed to produce a feed for light neutral base stock production and a feed for heavy neutral base stock production. The 343 °C+ portion of the feed for light neutral base stock production can have a kinematic viscosity at 100°C of 1.5 cSt to 6.5 cSt, or 2.0 cSt to 6.0 cSt, or 2.0 cSt to 5.0 cSt, or 1.5 cSt to 4.5 cSt. It is noted that the feed for light neutral base stock production may include some fuels boiling range components (343°C- ), so the kinematic viscosity of the full feed to the second stage for light neutral base stock production may be lower than the above listed ranges. The feed for heavy neutral base stock production can have a kinematic viscosity at 100°C of 6.0 cSt or more, or 6.5 cSt or more, or 8.0 cSt or more, such as up to 16 cSt or still higher. It is noted that the feed for heavy neutral base stock production may correspond to a bottoms fraction, and therefore may have a viscosity above the typical viscosity for a heavy neutral lubricant base stock. In various aspects, the kinematic viscosity at 100°C for the feed for heavy neutral base stock production can be at least 2.0 cSt higher than the kinematic viscosity at 100°C for the feed for light neutral base stock production, or at least 2.5 cSt higher, or at least 3.0 cSt higher, such as up to 6.0 cSt higher or possibly more.

[0042] As an example of processing, an initial feedstock can correspond to a typical or conventional feedstock for lubricant base stock production. A first processing stage can perform an initial amount of hydrotreating and/or hydrocracking. A first separation stage can then be used to remove fuels boiling range (and lower boiling range) compounds. The first separation stage can also be used to separate the lubricant boiling range portion of the effluent into a feed for light neutral processing and a feed for heavy neutral processing. These separate feeds can be stored, to allow for block operation of the second stage of the processing system. During blocked operation of the second stage, the light neutral feed or heavy neutral feed can be passed into a first reactor and exposed under hydrocracking conditions to a USY catalyst including a supported noble metal, such as Pt and/or Pd. The USY catalyst can have a desirable combination of catalyst properties, such as a unit cell size of 24.30 or less (or 24.24 or less), a silica to alumina ratio of at least 50 (or at least 80), and an alpha value of 20 or less (or 10 or less). The conversion conditions for the heavy neutral feed can be substantially less severe relative to the conversion conditions for the light neutral feed, as less viscosity index uplift is required for the resulting heavy neutral product. The hydrocracked effluent can then be passed into a dewaxing reactor. The dewaxing reactor can include both aromatic saturation catalyst and dewaxing catalyst, with at least a portion of the aromatic saturation catalyst being upstream from the dewaxing catalyst. During the portion of block operation for processing of the heavy neutral feed, the additional aromatic saturation catalyst in the upstream portion of the reactor can assist with reducing the aromatics content of the heavy neutral feed. The dewaxed effluent can then be passed into a hydrofinishing reactor for additional aromatic saturation. A final separation can be performed either on the dewaxed effluent prior to hydrofinishing or on the hydrofinished effluent to separate any additional fuels boiling range material and/or light ends from the desired lubricant base stock product.

[0043] Optionally, further reductions in aromatics content can be achieved by using a recycle quench stream. In various aspects, use of a recycle quench stream can allow the effluent from a USY hydrocracking reactor to be passed into a dewaxing reactor without intermediate separation while also allowing for greater relative control of various temperatures. For example, the temperature of the hydrocracked effluent at the inlet to the dewaxing reactor can be at least 10°F (~5°C) cooler than the temperature of the input feed to the USY hydrocracking reactor, or at least 20°F (~10°C) cooler, such as up to 40°F (~20°C) cooler or more. Additionally or alternately, the temperature of the hydrocracked effluent at the inlet to the dewaxing reactor can be at least 40°F (~20°C) cooler than the temperature of the hydrocracked effluent at the exit from the USY hydrocracking reactor, or at least 50°F (~25°C), or at least 60°F (~30°C), such as up to 80°F (~40°C) or more. In order to cool the hydrocracked effluent, 20 wt% to 50 wt% of the dewaxed effluent can be recycled to a location prior to the inlet to the dewaxing reactor. The location for withdrawing the dewaxed effluent for recycle can be any convenient location after the dewaxing reactor and prior to fractionation of the dewaxed effluent. For example, if the dewaxing reactor includes a hydrofinishing catalyst and/or if the dewaxed effluent is passed into a separate hydrofinishing reactor prior to fractionation, the dewaxed effluent used for the recycle stream can correspond to a recycled portion of a dewaxed and hydrofinished effluent. In some aspects, the weight average bed temperature of the dewaxing reactor can be greater than the dewaxing reactor inlet temperature by 15°C or less, or by 10°C or less.

[0044] FIG. 1 shows an example of a general processing configuration suitable for block processing of a feedstock to produce multiple lubricant base stock products. In FIG. 1, a hydroprocessed feedstock 105 can be introduced into a separation stage 160, such as a fractionation tower. The hydroprocessed feedstock 105 can correspond to a "sweet" feedstock with a sulfur content of 250 wppm or less, or 100 wppm or less, or 50 wppm or less. Such a hydroprocessed feedstock can correspond to (at least a portion of) the hydroprocessed effluent from a first stage of a reaction system. The first stage can include one or more hydroprocessing reactors. Examples of suitable types of catalysts for the one or more hydroprocessing reactors can include hydrotreating catalysts, hydrocracking catalysts, and demetallization catalysts. Because the first stage is a sour processing stage, the catalysts in the one or more hydroprocessing reactors can typically include base metals. The hydroprocessed feedstock can be separated by separation stage 160 to form a variety of products. Based on the prior hydroprocessing, the hydroprocessed feedstock may include fuels boiling range compounds and/or light ends (including C ₄ - compounds and/or contaminant gases such as H2S). The hydroprocessed feedstock can also include a lubricant boiling range portion. In addition to separating the lubricant boiling range portion from (a substantial portion of) the fuels boiling range compounds, the separation stage 160 can also separate the lubricant boiling range portion into a first lubricant boiling range fraction 162 and a second lubricant boiling range fraction 167. The first lubricant boiling range fraction 162 can be stored, for example, in storage tank 170, while the second lubricant boiling range fraction 167 can be stored in storage tank 174. This can allow the fractions to be stored until the appropriate time for use, so that the sweet stage of the reaction system can be operated in a block processing mode.

[0045] During block processing, hydroprocessed feed 175 for input to hydrocracking reactor 110 can correspond either to first lubricant boiling range fraction 172 (from storage tank 170) or second lubricant boiling range fraction 177 (from storage tank 174). The hydroprocessed feed 175 can be passed into hydrocracking reactor 110 under conditions that are selected based on a desired degree of viscosity index uplift in the resulting hydrocracked effluent 115. For a light neutral feed, higher severity conditions can be selected, such as hydrocracking conditions with sufficient conversion so that the 343°C+ portion or a 371°C+ portion of the hydrocracked effluent has a viscosity index of 120 or more, or 125 or more, or 130 or more, such as up to 145 or possibly still higher. For a heavy neutral feed, lower severity conditions can be selected, such as hydrocracking conditions with conversion that results in a hydrocracked effluent with a viscosity index of 100 or less, or 95 or less, or 90 or less, such as down to 80 or possibly still lower. The hydrocracked effluent 115 can optionally undergo separation to remove lower boiling material, or the hydrocracked effluent 115 can be passed into dewaxing reactor 120. In addition to dewaxing catalyst, dewaxing reactor 120 can also include an initial portion of aromatic saturation catalyst that is upstream from the dewaxing catalyst. Dewaxing reactor 120 can generate a dewaxed effluent 125. Dewaxed effluent 125 can then be passed into hydrofinishing reactor 140 for additional aromatic saturation. The hydrofinished effluent 145 can then be fractionated 150 to separate the desired lubricant product 157 from other portions of the hydrocracked effluent, such as a light ends and/or fuels portion 151, a lighter lubricant product fraction 152, and/ or a heavier portion 159 that may have been co-processed with the heavy neutral fraction. Optionally, the dewaxed effluent 125 can be fractionated 150 prior to being passed into hydrofinishing reactor 140.

[0046] In hydrocracking reactor 110, one or more of the catalyst beds can optionally contain catalyst different from a hydrocracking catalyst. For example, an initial catalyst bed (or portion thereof) and/or a final catalyst bed (or portion thereof) in hydrocracking reactor 110 can include aromatic saturation catalyst for further reducing the aromatics content of a feed. Similarly, an initial catalyst bed (or portion thereof) and/or a final catalyst bed (or portion thereof) in dewaxing reactor 120 can include aromatic saturation catalyst for further reducing the aromatics content of a feed

[0047] The configuration in FIG. 1 shows details of the configuration related to blocked operation. FIG. 2 shows another configuration for the sweet processing stage of a reaction system for production of lubricant base stocks. The configuration shown in FIG. 2 provides additional details regarding an example of temperature and flow management within a reaction system. It is understood that the features shown in FIG. 1 and FIG. 2 can be used separately or in conjunction with each other.

[0048] In FIG. 2, a hydroprocessed feed 175 can be passed into a feed heater 280 prior to entering hydrocracking reactor 110. Feed heater 280 can be any convenient type of heater that is suitable for heating of hydrocarbonaceous feeds. In the example shown in FIG. 2, feed heater 280 can also include a flow path for heating a portion of a hydrogen-containing stream 101. The feed heater 280 can contribute to control over the inlet temperature for hydrocracking reactor 110 and/or dewaxing reactor 120 based on heating of hydroprocessed feed 175 and heating of a portion of hydrogen-containing stream 101. After heating, the heated hydroprocessed feed 275 can be passed into hydrocracking reactor 110. Optionally, a portion 278 of the heated hydroprocessed feed 275 can be introduced at a downstream location within reactor 110, such as a location that allows portion 278 to not be exposed to one or more catalyst beds within reactor 110. With regard to hydrogen-containing stream 101, a heated portion 281 of the hydrogen-containing stream can be introduced into hydrocracking reactor 1 10 as part of the feed or as a separate stream. Similarly, a heated portion 282 of the hydrogen-containing stream can be introduced into dewaxing reactor 120 as part of the feed or as a separate stream. In the example shown in FIG. 2, heated portion 281 is mixed with heated hydroprocessed feed 275 prior to entering reactor 110, while heated portion 282 is introduced into reactor 120 directly. It is noted that heated portion 281 and heated portion 282 of the hydrogen-containing stream can be used selectively. For example, heated portion 281 can be used when a higher temperature is desired in hydrocracking reactor 110, such as during processing of a heated hydroprocessed feed 275 for production of a high viscosity index light neutral base stock. During processing of a corresponding feed for heavy neutral base stock production, heated portion 281 may be omitted, and non-heated hydrogen 211 may be mixed with heated hydroprocessed feed 275 instead. Still another option can be to use both heated portion 281 and non-heated hydrogen 211 in a desired ratio. For dewaxing reactor 120, heated portion 282 may be used during processing to form a heavy neutral base stock, as the temperature of hydrocracking reactor 110 can be lower during the lower conversion processing used for heavy neutral production. As a result, hydrocracked effluent 115 can have a lower temperature during heavy neutral base stock production, and heated portion 282 of the hydrogen-containing stream can be used to increase the inlet temperature for dewaxing reactor 120. If additional heat is not required (or if less heat is required), non-heated hydrogen 221 can be used alone or in combination with heated portion 282.

[0049] In addition to heater 280 and the associated flows heated by heater 280, it is noted that heat exchangers (not shown) can also be included at any convenient location in the configuration in FIG. 2 to further assist with temperature management.

[0050] Further temperature control can be provided by using cooling (or quench) stream 223 and cold hydrogen stream 243. Cooling stream 223 and cold hydrogen stream 243 can allow for control of temperature prior to the final catalyst bed(s) in reactors 120 and 140, respectively. In the example shown in FIG. 2, reactor 120 can include a first bed of aromatic saturation catalyst, 3 middle beds of dewaxing catalyst, and a final bed of aromatic saturation catalyst. Cooling stream 223 can allow for the feed in the dewaxing reactor 120 to be exposed to the final aromatic saturation catalyst at a lower temperature. This can be beneficial for shifting the equilibrium value of aromatics in the feed. Similarly, cold hydrogen stream 243 can allow for the feed in the aromatic saturation reactor 140 to be exposed to the final aromatic saturation catalyst(s) at a lower temperature.

[0051] FIG. 3 shows an example of a first stage of a processing system. FIG. 3 includes flows for either processing an entire feed 305 or for blocking of a feed 365 in the first stage of the processing system. For processing of a feed 305 without blocking, the feed 305 can be introduced into a hydroprocessing reactor 390. In FIG. 3, two hydroprocessing reactors 390 and 394 are shown, but it is understood that any convenient number of hydroprocessing reactors can be used. The hydroprocessing reactors can include demetallization catalysts, hydrotreating catalysts, and/or hydrocracking catalysts. In the example shown in FIG. 3, the effluent 392 from reactor 390 can be passed into an additional reactor 394. This can correspond to, for example, having a first reactor 390 that contains a hydrotreating catalyst and a second reactor 394 that contains (base metal) hydrocracking catalyst. Optionally, a separation (not shown) could be performed between reactors 390 and 394. After the final reactor, such as reactor 394 in FIG. 3, the effluent 396 from the final reactor can be used a hydroprocessed feed in the second stage of the reaction system.

[0052] If the first stage of the reaction system is operated to perform block processing, a feed 365 can first be introduced into a fractionator 360 to generate a light neutral feed fraction 362 and a heavy neutral feed fraction 367. These feed fractions can be stored in storage tanks 380 and 384, respectively. Either light neutral feed 382 or heavy neutral feed 387 can then be used as the input feed 385 to first hydroprocessing reactor 390. The final reactor effluent 396 can correspond to an effluent that can be passed into an appropriate storage tank (such as storage 170 or 174), or the effluent can be passed directly into the second stage reactors in the reaction system.

[0053] FIG. 4 schematically shows another example of a reaction system including a plurality of reactors that can be used, for example, as the sweet stage of a reaction for producing lubricant base stocks. The configuration in FIG. 4 provides an example of a reaction system that can independently heat multiple reactors within a reaction system. This is in contrast to conventional reaction systems, where typically a single hydrogen inlet and/or inert gas inlet is used when heating the reaction system. If only a single inlet is used for heating a multi-reactor system, the inlet temperatures for the plurality of reactors in the multi-reactor system can be linked in a substantial manner. By contrast, the configuration shown in FIG. 4 can provide additional flexibility to independently choose inlet temperatures for two or more reactors from the plurality of reactors in the multi-reactor system.

[0054] In FIG. 4, a hydrogen input stream from a hydrogen source 405 is passed through valve 406 into a heater 410. In the configuration shown in FIG. 4, hydrogen input stream 405 and feed 401 are shown as being combined prior to entering the heater to form a single heated output stream 414. In other aspects, multiple heated output streams 414 can be used, such as a first heated output stream containing heated hydrogen and a second heated output stream containing heated feed. More generally, it is understood that any convenient number of input and/or output streams can be used in conjunction with one or more heaters 410 for forming heated feed streams and heated hydrogen stream. It is noted that valves 406 and 402 can be used to control when hydrogen 405 and feed 401, respectively, are passed through heater 410 to form heated output stream 414. For example, as shown in FIG. 4, if valve 406 is open and valve 402 is closed, then heated output stream 414 can correspond to a heated hydrogen stream.

[0055] The heated hydrogen in heated output stream 414 can be used for a variety of purposes. When desired, heated hydrogen from heated output stream 414 can be passed into first reactor 420. Additionally, second heated hydrogen stream 431 and third heated hydrogen stream 441 can be optionally introduced into the second reactor 430 and third reactor 440, respectively. These optional hydrogen streams can be introduced at any convenient time. Thus, the optional hydrogen lines can be used prior to feed processing, such as during catalyst activation; during feed processing, such as to facilitate independent control over temperatures in the reactors in a reaction system; or after feed processing, such as for regeneration of a catalyst. In FIG. 4, reactors 420, 430, and 440 can represent any convenient type of reactors suitable for processing a feed in the presence of hydrogen and a catalyst. The catalysts in reactors 420, 430, and 440 can be the same or different. Optionally, at least one of reactors 420, 430, and 440 can contain a noble metal catalyst having a highly siliceous support. More generally, any convenient number of reactors can be present, such as a plurality of reactors.

[0056] During operation of the reactors for processing of a feed, feed 401 and hydrogen 405 from heated output 414 can be introduced into reactor 420. The hydroprocessing in reactor 420 can result in a hydroprocessed effluent 425. Optionally, at least a portion of the hydroprocessed effluent 425 can be passed through a heat exchanger 426 and/or another heating or cooling device for adjustment of the temperature of hydroprocessed effluent 425. The hydroprocessed effluent 425, after optional temperature adjustment, can then be passed into reactor 430. The hydroprocessing in reactor 430 can result in a second hydroprocessed effluent 435. Optionally, at least a portion of the second hydroprocessed effluent 435 can be passed through a heat exchanger 436 and/or another heating or cooling device for adjustment of the temperature of the second hydroprocessed effluent 435. The second hydroprocessed effluent 435, after optional temperature adjustment, can then be passed into reactor 440 for processing to form third hydroprocessed effluent 445. After optional temperature adjustment 446, the third hydroprocessed effluent 445 can be further processed, fractionated, stored in drums, or disposed of / used in any convenient manner.

[0057] It is noted that the additional heated hydrogen lines, represented by heated hydrogen lines 431 and 441 in FIG. 4, can enable other types of processing within a reaction system in addition to catalyst activation. As an example, a hypothetical system could include noble metal catalysts in both reactor 430 and reactor 440, such as a noble metal dewaxing catalyst in reactor 430 and a noble metal hydrofinishing catalyst in reactor 440. For such a reaction system, process "upsets" can occur from time to time, where an undesirable feed and/or a less than full processed feed may be able to enter downstream reactors, such as reactors 430 and 440. When such a process upset occurs, the undesirable feed may contaminate the catalyst beds in the reactors, and this may cause catalyst deactivation and/or poisoning. In order to restore catalyst activity, it may be desirable to expose the catalysts in the reaction system to a cleaning feed at an elevated temperature. However, if the only heat source available is the heater for the feed into the initial stage, as the cleaning feed passes through the reactors, the feed will lose temperature and can be substantially cooler by the time the feed reaches the final reactor in a reaction system. One option could be to increase the cleaning feed temperature into the initial reactor, but temperatures above roughly 385°C could lead to thermal cracking and coking in the presence of a catalyst, which can place effective limits on the temperature in the final reactor(s). Having independent heated hydrogen lines can assist with achieving higher temperatures during a regeneration or cleaning cycle without having to risk catalyst coking in earlier reactors.

[0058] It is noted that the configurations shown in FIGS. 1 - 4 provide various examples of process elements (reactors, fractionators, heaters, etc.) that are in fluid communication with one another. Process elements can be in direct fluid communication or indirect fluid communication with another process element. For example, in FIG. 2 the outlet of hydrocracking reactor 110 is shown as being in direct fluid communication with the inlet of dewaxing reactor 120. The outlet of hydrocracking reactor 110 is in indirect fluid communication with hydrofinishing reactor 140, based on the intervening presence of dewaxing reactor 120. It is noted that process elements that do not alter the composition of a flow, such as a heat exchanger, may be included within a direct fluid communication flow path.

[0059] In this discussion, reference may be made to operating a reactor at substantially similar conditions during different phases of blocked operation. For example, during blocked operation of the second stage of a reaction system, the conditions for hydrocracking may differ substantially for light neutral base stock production and heavy neutral base stock production, while the conditions for the dewaxing reactor and the hydrofinishing reactor are substantially similar for production of both types of base stocks. In this discussion, substantially similar conditions for operating a reactor are defined as processing conditions where the temperature, pressure, LHSV, and hydrogen treat gas rate differ by less than specified relative amounts between processing of the feed types. Substantially similar conditions for a reactor are defined as a) an inlet temperature that differs by 10°C or less between light neutral and heavy neutral processing; b) an exit temperature that differs by 10°C or less between light neutral and heavy neutral processing; c) an inlet pressure that differs by less than 5% of the highest pressure value between light neutral and heavy neutral processing; d) a LHSV that differs by 0.12 hr ^"1 or less between light neutral and heavy neutral processing; and e) a hydrogen treat gas rate that differs by less than 10% of the highest treat gas rate between light neutral and heavy neutral processing. It is noted that for the hydrogen treat gas rate, the difference between the rates is calculated based on the rate of hydrogen flow only. If inerts (such as nitrogen) are present in the treat gas, only the percentage of the flow corresponding to hydrogen should be considered.

[0060] In this discussion, the naphtha boiling range is defined as 50°F (~10°C, roughly corresponding to the lowest boiling point of a pentane isomer) to 315°F (157°C). The jet boiling range is defined as 315°F (157°C) to 460°F (238°C). The diesel boiling range is defined as 460°F (238°C) to 650°F (343°C). The distillate fuel boiling range (jet plus diesel), is defined as 315°F (157°C) to 650°F (343°C). The fuels boiling range is defined as ~10°C to 343°C. The lubricant boiling range is defined as 650°F (343°C) to 1050°F (566°C). Optionally, when forming a lubricant boiling portion by fractionation after one or more stages of hydroprocessing (e.g., hydrotreating, hydrocracking, catalytic dewaxing, hydrofinishing), a lubricant boiling range portion can optionally correspond to a bottoms fraction, so that higher boiling range compounds may also be included in the lubricant boiling range portion. Compounds (C ₄ -) with a boiling point below the naphtha boiling range can be referred to as light ends. It is noted that due to practical consideration during fractionation (or other boiling point based separation) of hydrocarbon-like fractions, a fuel fraction formed according to the methods described herein may have T5 and T95 distillation points corresponding to the above values (or T10 and T90 distillation points), as opposed to having initial / final boiling points corresponding to the above values.

[0061] In this discussion, unless otherwise specified, references to a liquid effluent or a liquid product are references to an effluent or product that is a liquid at 25°C and 100 kPa-a (~1 atm).

[0062] In this discussion, conditions may be provided for various types of hydroprocessing of feeds or effluents. Examples of hydroprocessing can include, but are not limited to, one or more of hydrotreating, demetallization, hydrocracking, catalytic dewaxing, and hydrofinishing / aromatic saturation. Such hydroprocessing conditions can be controlled to have desired values for the conditions (e.g., temperature, pressure, LHSV, treat gas rate) by using at least one controller, such as a plurality of controllers, to control one or more of the hydroprocessing conditions. In some aspects, for a given type of hydroprocessing, at least one controller can be associated with each type of hydroprocessing condition. In some aspects, one or more of the hydroprocessing conditions can be controlled by an associated controller. Examples of structures that can be controlled by a controller can include, but are not limited to, valves that control a flow rate, a pressure, or a combination thereof; heat exchangers and/or heaters that control a temperature; and one or more flow meters and one or more associated valves that control relative flow rates of at least two flows. Such controllers can optionally include a controller feedback loop including at least a processor, a detector for detecting a value of a control variable (e.g., temperature, pressure, flow rate, and a processor output for controlling the value of a manipulated variable (e.g., changing the position of a valve, increasing or decreasing the duty cycle and/or temperature for a heater). Optionally, at least one hydroprocessing condition for a given type of hydroprocessing may not have an associated controller.

[0063] Group I basestocks or base oils are defined as base oils with less than 90 wt% saturated molecules and/or at least 0.03 wt% sulfur content. Group I basestocks also have a viscosity index (VI) of at least 80 but less than 120. Group II basestocks or base oils contain at least 90 wt% saturated molecules and less than 0.03 wt% sulfur. Group II basestocks also have a viscosity index of at least 80 but less than 120. Group III basestocks or base oils contain at least 90 wt% saturated molecules and less than 0.03 wt% sulfur, with a viscosity index of at least 120. In addition to the above formal definitions, some Group I basestocks may be referred to as a Group 1+ basestock, which corresponds to a Group I basestock with a VI value of 103 to 108. Some Group II basestocks may be referred to as a Group 11+ basestock, which corresponds to a Group II basestock with a VI of at least 113. Some Group III basestocks may be referred to as a Group III+ basestock, which corresponds to a Group III basestock with a VI value of at least 140.

Feedstocks

[0064] A wide range of petroleum and chemical feedstocks can be hydroprocessed in accordance with the invention. Suitable feedstocks include whole and reduced petroleum crudes, atmospheric, cycle oils, gas oils, including vacuum gas oils and coker gas oils, light to heavy distillates including raw virgin distillates, hydrocrackates, hydrotreated oils, slack waxes, Fischer- Tropsch waxes, raffinates, deasphalted oils, and mixtures of these materials.

[0065] As noted above, the feedstock can optionally include desaphalted oil. In some aspects, a deasphalted oil can correspond to a low lift deasphalted oil, such as a deasphalted oil formed by deasphalting a vacuum resid boiling range feed (T10 distillation point of 510°C or more) to produce a yield of deasphalted oil of roughly 40 wt% or less, or 35 wt% or less, or 30 wt% or less, such as down to 20 wt% or possibly still lower. This can correspond to, for example, a deasphalted oil formed by conventional propane deasphalting of a vacuum resid boiling range feed. In other aspects, a deasphalted oil can correspond to a high lift deasphalted oil, such as a deasphalted oil formed by deasphalting a vacuum resid boiling range feed (T10 distillation point of 510°C or more) to produce a yield of deasphalted oil of at least 50 wt%, or at least 60 wt%, or at least 65 wt%, or at least 70 wt% such as up to 80 wt% or possibly still higher. This can correspond to, for example, a deasphalted oil formed by deasphalting using a C ₄ + solvent or a Cs+ solvent. A Cn+ solvent is defined as a hydrocarbon solvent that includes at least 50 wt% of alkanes that contain "n" carbons or more, or at least 75 wt%, such as up to the solvent being substantially completely composed of alkanes that contain "n"carbons or more. Butane is an example of a C ₄ solvent. Pentane, hexane, and heptane are examples of Cs+ solvents. It is noted that alkanes can include n-alkanes and branched alkanes.

[0066] One way of defining a feedstock is based on the boiling range of the feed. One option for defining a boiling range is to use an initial boiling point for a feed and/or a final boiling point for a feed. Another option is to characterize a feed based on the amount of the feed that boils at one or more temperatures. For example, a "T5" boiling point / distillation point for a feed is defined as the temperature at which 5 wt% of the feed will boil off. Similarly, a "T95" boiling point / distillation point is a temperature at 95 wt% of the feed will boil. Boiling points, including fractional weight boiling points, can be determined using a suitable ASTM method, such as ASTM D2887.

[0067] Typical feeds include, for example, feeds with an initial boiling point and/or a T5 boiling point and/or TIO boiling point of at least 600°F (~316°C), or at least 650°F (~343°C), or at least 700°F (37FC), or at least 750°F (~399°C). Additionally or alternately, the final boiling point and/or T95 boiling point and/or T90 boiling point of the feed can be 1100°F (~593°C) or less, or 1050°F (~566°C) or less, or 1000°F (~538°C) or less, or 950°F (~510°C) or less. In particular, a feed can have a T5 to T95 boiling range of 600°F (~316°C) to 1100°F (~593°C), or a T5 to T95 boiling range of 650°F (~343°C) to 1050°F (~566°C), or a TIO to T90 boiling range of 650°F (~343°C) to 1050°F (~566°C) Optionally, if the hydroprocessing is also used to form fuels, it can be possible to use a feed that includes a lower boiling range portion. Such a feed can have an initial boiling point and/or a T5 boiling point and/or TIO boiling point of at least 350°F (~177°C), or at least 400°F (~204°C), or at least 450°F (~232°C). In particular, such a feed can have a T5 to T95 boiling range of 350°F (~177°C) to 1100°F (~593°C), or a T5 to T95 boiling range of 450°F (~232°C) to 1050°F (~566°C), or a TIO to T90 boiling range of 350°F (~177°C) to 1050°F (~566°C).

[0068] In some aspects, the aromatics content of the feed can be at least 20 wt%, or at least 30 wt%, or at least 40 wt%, or at least 50 wt%, or at least 60 wt%. In particular, the aromatics content can be 20 wt% to 90 wt%, or 40 wt% to 80 wt%, or 50 wt% to 80 wt%.

[0069] In aspects where the hydroprocessing includes a hydrotreatment process and/or a sour hydrocracking process, the feed can have a sulfur content of 500 wppm to 20000 wppm or more, or 500 wppm to 10000 wppm, or 500 wppm to 5000 wppm. Additionally or alternately, the nitrogen content of such a feed can be 20 wppm to 4000 wppm, or 50 wppm to 2000 wppm. In some aspects, the feed can correspond to a "sweet" feed, so that the sulfur content of the feed is 10 wppm to 500 wppm and/or the nitrogen content is 1 wppm to 100 wppm.

[0070] In some embodiments, at least a portion of the feed can correspond to a feed derived from a biocomponent source. In this discussion, a biocomponent feedstock refers to a hydrocarbon feedstock derived from a biological raw material component, from biocomponent sources such as vegetable, animal, fish, and/or algae. Note that, for the purposes of this document, vegetable fats/oils refer generally to any plant based material, and can include fat/oils derived from a source such as plants of the genus Jatropha. Generally, the biocomponent sources can include vegetable fats/oils, animal fats/oils, fish oils, pyrolysis oils, and algae lipids/oils, as well as components of such materials, and in some embodiments can specifically include one or more type of lipid compounds. Lipid compounds are typically biological compounds that are insoluble in water, but soluble in nonpolar (or fat) solvents. Non-limiting examples of such solvents include alcohols, ethers, chloroform, alkyl acetates, benzene, and combinations thereof.

Second Stage Hydrocracking

[0071] In various aspects, the second stage for processing a feedstock can include exposing at least a portion of the feedstock to a hydrocracking catalyst under hydrocracking conditions. The exposure to a hydrocracking catalyst can occur in the first reactor(s) of a plurality of reactors in the second stage, with the second stage hydrocracked effluent subsequently be exposed to catalyst in one or more additional reactors, such as a reactor including dewaxing catalyst and/or a reactor including hydrofinishing catalyst.

[0072] Hydrocracking catalysts typically contain sulfided base metals on acidic supports, such as amorphous silica alumina; cracking zeolites such as USY, zeolite Beta, or ZSM-5; or acidified alumina. Often these acidic supports are mixed or bound with other metal oxides such as alumina, titania or silica. Non-limiting examples of metals for hydrocracking catalysts include nickel, nickel- cobalt-molybdenum, cobalt-molybdenum, nickel-tungsten, nickel-molybdenum, and/or nickel- molybdenum-tungsten. Additionally or alternately, hydrocracking catalysts with noble metals can also be used. Non-limiting examples of noble metal catalysts include those based on platinum and/or palladium. Support materials which may be used for both the noble and non-noble metal catalysts can comprise a refractory oxide material such as alumina, silica, alumina-silica, kieselguhr, diatomaceous earth, magnesia, zirconia, or combinations thereof, with alumina, silica, alumina-silica being the most common (and preferred, in one embodiment).

[0073] In aspects where a hydrocracking catalyst includes Group VIII noble metals, such as for hydrocracking in a "sweet" hydrocracking stage, the one or more Group VIII metals can be present in an amount ranging from 0.1 wt% to 5.0 wt%, or 0.1 wt% to 2.0 wt%, or 0.3 wt% to 2.0 wt%, or 0.1 wt% to 1.5 wt%, or 0.3 wt% to 1.5 wt%. In aspects where a hydrocracking catalyst includes base metals, the at least one Group VIII non-noble metal, in oxide form, can typically be present in an amount ranging from 2 wt% to 40 wt%, preferably from 4 wt% to 15 wt%. The at least one Group VIB metal, in oxide form, can typically be present in an amount ranging from 2 wt% to 70 wt%, preferably for supported catalysts from 6 wt% to 40 wt% or from 10 wt% to 30 wt%. These weight percents are based on the total weight of the catalyst. In some aspects, suitable hydrocracking catalysts can include nickel/molybdenum, nickel/tungsten, or nickel/molybdenum/tungsten as metals supported on the hydrocracking catalyst.

[0074] In some aspects, a hydrocracking catalyst can include a large pore molecular sieve that is selective for cracking of branched hydrocarbons and/or cyclic hydrocarbons. Zeolite Y, such as ultrastable zeolite Y (USY) is an example of a zeolite molecular sieve that is selective for cracking of branched hydrocarbons and cyclic hydrocarbons. Depending on the aspect, the silica to alumina ratio in a USY zeolite can be at least 10, such as at least 15, or at least 25, or at least 50, or at least 100. Depending on the aspect, the unit cell size for a USY zeolite can be 24.50 Angstroms or less, such as 24.45 Angstroms or less, or 24.40 Angstroms or less, or 24.35 Angstroms or less, such as 24.30 Angstroms (or less). In other aspects, a variety of other types of molecular sieves can be used in a hydrocracking catalyst, such as zeolite Beta and ZSM-5. Still other types of suitable molecular sieves can include molecular sieves having 10-member ring pore channels or 12-member ring pore channels. Examples of molecular sieves having 10-member ring pore channels or 12-member ring pore channels include molecular sieves having zeolite framework structures selected from MRE, MTT, EUO, AEL, AFO, SFF, STF, TON, OSI, ATO, GON, MTW, SFE, SSY, or VET.

[0075] In some aspects, the second stage for processing of a feedstock can correspond to exposing at least a portion of the feedstock to a USY catalyst with a desirable combination of properties. The properties can be measured prior to the addition of loaded metals on the catalyst. The USY catalyst can have a unit cell size of 24.30 A or less, or 24.27 A or less, or 24.24 A or less. Additionally or alternately, the USY catalyst can have a silica to alumina ratio of at least 50, or at least 70, or at least 90, or at least 100, or at least 110, or at least 120, or at least 125, and optionally up to 250 or more, or not more than 1000. This level of silica to alumina ratio can correspond to a "dealuminated" version of the catalyst. Additionally or alternately, the USY catalyst can have an alpha value of 20 or less, or 10 or less. The alpha value test is a measure of the cracking activity of a catalyst and is described in U.S. Pat. No. 3,354,078 and in the Journal of Catalysis, Vol. 4, p. 527 (1965); Vol. 6, p. 278 (1966); and Vol. 61, p. 395 (1980), each incorporated herein by reference as to that description. The experimental conditions of the test used herein include a constant temperature of 538° C. and a variable flow rate as described in detail in the Journal of Catalysis, Vol. 61, p. 395.

[0076] A USY hydrocracking catalyst can also include a binder material. Suitable binder materials include materials selected from metal oxides, zeolites, aluminum phosphates, polymers, carbons, and clays. Most preferable, the binder is comprised of at least one metal oxide, preferably selected from silica, alumina, silica-alumina, amorphous aluminosilicates, boron, titania, and zirconia. Preferably, the binder is selected from silica, alumina, and silica-alumina. In a preferred embodiment, the binder is comprised of pseudoboehmite alumina.

[0077] A catalyst can contain from 0 to 99 wt% binder materials, or 25 to 80 wt%, or 35 to 75 wt%, or 50 to 65 wt% of the overall final hydrocracking catalyst. In other preferred embodiments, a hydrocracking catalyst can be less than 80 wt% binder materials, or less than 75 wt%, or less than 65 wt%, or less than 50 wt%.

[0078] A hydrocracking catalyst containing USY zeolite may also contain additional zeolites or molecular sieves. In some aspects, a hydrocracking catalyst can further comprise at least one of the following molecular sieves: beta, ZSM-5, ZSM-11, ZSM-57, MCM-22, MCM-49, MCM-56, ITQ-7, ITQ-27, ZSM-48, mordenite, zeolite L, ferrierite, ZSM-23 MCM-68, SSZ-26/-33, SAPO- 37, ZSM-12, ZSM-18, and EMT faujasites. In such aspects, the hydrocracking catalyst can contain the EMY zeolite in an amount of at least 10 wt %, more preferably at least at least 25 wt %, and even more preferably at least 35 wt % or even at least 50 wt % based on the finished catalyst, particularly when a binder is utilized.

[0079] A USY hydrocracking catalyst can also include at least one hydrogenating metal component supported on the catalyst. Examples of such hydrogenating metal components can include one or more noble metals from Groups 8 - 10 of the IUPAC periodic table. Optionally but preferably, the hydrocracking catalyst can include at least one Group 8/9/10 metal selected from Pt, Pd, Rh and Ru (noble metals), or combinations thereof. In an aspect, the hydrocracking catalyst can comprise at least one Group 8/9/10 metal selected from Pt, Pd, or a combination thereof. In an aspect, the hydrocracking catalyst can comprise Pt. The at least one hydrogenating metal may be incorporated into the catalyst by any technique known in the art. A preferred technique for active metal incorporation into the catalyst herein is the incipient wetness technique.

[0080] The amount of active metal in the catalyst can be at least 0.1 wt % based on catalyst, or at least 0.15 wt %, or at least 0.2 wt %, or at least 0.25 wt %, or at least 0.3 wt %, or at least 0.5 wt % based on the catalyst. For embodiments where the Group 8/9/10 metal is Pt, Pd, Rh, Ru, or a combination thereof, the amount of active metal is preferably from 0.1 to 5 wt %, more preferably from 0.2 to 4 wt %, and even more preferably from 0.25 to 3.5 wt %.

[0081] Hydrocracking conditions in the second stage (under "sweet" conditions with a sulfur content of 250 wppm or less, or 100 wppm or less) can include a temperature of from 200 to 450°C, preferably 270 to 400°C, a hydrogen partial pressure of from 1.8 to 34.6 MPag (-250 to -5000 psi), preferably 4.8 to 20.8 MPag, a liquid hourly space velocity of from 0.2 to 10 hr ^"1 , preferably 0.5 to 3.0 hr ^"1 , and a hydrogen circulation rate of from 35.6 to 1781 m ³ /m ³ (-200 to -10,000 SCF/B), preferably 178 to 890.6 m ³ /m ³ (-1000 to -5000 scf/B). Additionally or alternately, the conditions can include temperatures in the range of 600°F (~343°C) to 815°F (~435°C), hydrogen partial pressures of from 500 psig to 3000 psig (-3.5 MPag to -20.9 MPag), and hydrogen treat gas rates of from 213 m ³ /m ³ to 1068 m ³ /m ³ (-1200 SCF/B to -6000 SCF/B). [0082] Examples of suitable zeolite Y catalysts for the processes described herein can include catalysts based on aggregated Y zeolite (or Meso-Y) and Extra Mesoporous Y ("EMY") zeolite. Additional description of aggregated Y zeolite (Meso-Y) can be found in U.S. Patent 8,778,171, which is incorporated herein by reference with regard to description of aggregated Y zeolite and methods for making a catalyst containing aggregated Y zeolite. Additional description of Extra Mesoporous Y zeolite can be found in U.S. Patent 8,932,454, which is incorporated herein by reference with regard to description of EMY zeolite and methods for making a catalyst containing EMY zeolite.

First Hydroprocessing Stage - Hydrotreating and/or Hydrocracking

[0083] In various aspects, a first hydroprocessing stage can be used to improve one or more qualities of a feedstock for lubricant base oil production. Examples of improvements of a feedstock can include, but are not limited to, reducing the heteroatom content of a feed, performing conversion on a feed to provide viscosity index uplift, and/or performing aromatic saturation on a feed.

[0084] With regard to heteroatom removal, the conditions in the initial hydroprocessing stage (hydrotreating and/or hydrocracking) can be sufficient to reduce the sulfur content of the hydroprocessed effluent to 250 wppm or less, or 200 wppm or less, or 150 wppm or less, or 100 wppm or less, or 50 wppm or less, or 25 wppm or less, or 10 wppm or less. In particular, the sulfur content of the hydroprocessed effluent can be 1 wppm to 250 wppm, or 1 wppm to 50 wppm, or 1 wppm to 10 wppm. Additionally or alternately, the conditions in the initial hydroprocessing stage can be sufficient to reduce the nitrogen content to 100 wppm or less, or 50 wppm or less, or 25 wppm or less, or 10 wppm or less. In particular, the nitrogen content can be 1 wppm to 100 wppm, or 1 wppm to 25 wppm, or 1 wppm to 10 wppm.

[0085] In aspects that include hydrotreating as part of the initial hydroprocessing stage, the hydrotreating catalyst can comprise any suitable hydrotreating catalyst, e.g., a catalyst comprising at least one Group 8 - 10 non-noble metal (for example selected from Ni, Co, and a combination thereof) and at least one Group 6 metal (for example selected from Mo, W, and a combination thereof), optionally including a suitable support and/or filler material (e.g., comprising alumina, silica, titania, zirconia, or a combination thereof). The hydrotreating catalyst according to aspects of this invention can be a bulk catalyst or a supported catalyst. Techniques for producing supported catalysts are well known in the art. Techniques for producing bulk metal catalyst particles are known and have been previously described, for example in U.S. Patent No. 6,162,350, which is hereby incorporated by reference. Bulk metal catalyst particles can be made via methods where all of the metal catalyst precursors are in solution, or via methods where at least one of the precursors is in at least partly in solid form, optionally but preferably while at least another one of the precursors is provided only in a solution form. Providing a metal precursor at least partly in solid form can be achieved, for example, by providing a solution of the metal precursor that also includes solid and/or precipitated metal in the solution, such as in the form of suspended particles. By way of illustration, some examples of suitable hydrotreating catalysts are described in one or more of U.S. Patent Nos. 6,156,695, 6, 162,350, 6,299,760, 6,582,590, 6,712,955, 6,783,663, 6,863,803, 6,929,738, 7,229,548, 7,288,182, 7,410,924, and 7,544,632, U.S. Patent Application Publication Nos. 2005/0277545, 2006/0060502, 2007/0084754, and 2008/0132407, and International Publication Nos. WO 04/007646, WO 2007/084437, WO 2007/084438, WO 2007/084439, and WO 2007/084471, inter alia. Preferred metal catalysts include cobalt/molybdenum (1-10% Co as oxide, 10-40% Mo as oxide), nickel/molybdenum (1-10% Ni as oxide, 10-40%) Co as oxide), or nickel/tungsten (1-10% Ni as oxide, 10-40%> W as oxide) on alumina.

[0086] In various aspects, hydrotreating conditions can include temperatures of 200°C to 450°C, or 315°C to 425°C; pressures of 250 psig (-1.8 MPag) to 5000 psig (-34.6 MPag) or 500 psig (-3.4 MPag) to 3000 psig (-20.8 MPag), or 800 psig (-5.5 MPag) to 2500 psig (-17.2 MPag); Liquid Hourly Space Velocities (LHSV) of 0.2-10 h ^"1 ; and hydrogen treat rates of 200 scf/B (35.6 m ³ /m ³ ) to 10,000 scf/B (1781 m ³ /m ³ ), or 500 (89 m ³ /m ³ ) to 10,000 scf/B (1781 m ³ /m ³ ).

[0087] Hydrotreating catalysts are typically those containing Group 6 metals, and non-noble Group 8 - 10 metals, i.e., iron, cobalt and nickel and mixtures thereof. These metals or mixtures of metals are typically present as oxides or sulfides on refractory metal oxide supports. Suitable metal oxide supports include low acidic oxides such as silica, alumina or titania, preferably alumina. In some aspects, preferred aluminas can correspond to porous aluminas such as gamma or eta having average pore sizes from 50 to 200 A, or 75 to 150 A; a surface area from 100 to 300 m ² /g, or 150 to 250 m ² /g; and/or a pore volume of from 0.25 to 1.0 cm ³ /g, or 0.35 to 0.8 cmVg. The supports are preferably not promoted with a halogen such as fluorine as this generally increases the acidity of the support.

[0088] Alternatively, the hydrotreating catalyst can be a bulk metal catalyst, or a combination of stacked beds of supported and bulk metal catalyst. By bulk metal, it is meant that the catalysts are unsupported wherein the bulk catalyst particles comprise 30-100 wt. % of at least one Group 8 - 10 non-noble metal and at least one Group 6 metal, based on the total weight of the bulk catalyst particles, calculated as metal oxides and wherein the bulk catalyst particles have a surface area of at least 10 m ² /g. It is furthermore preferred that the bulk metal hydrotreating catalysts used herein comprise 50 to 100 wt %, and even more preferably 70 to 100 wt %, of at least one Group 8 - 10 non-noble metal and at least one Group 6 metal, based on the total weight of the particles, calculated as metal oxides. The amount of Group 6 and Group 8 - 10 non-noble metals can easily be determined VIB TEM-EDX.

[0089] Bulk catalyst compositions comprising one Group 8 - 10 non-noble metal and two Group 6 metals are preferred. It has been found that in this case, the bulk catalyst particles are sintering-resistant. Thus the active surface area of the bulk catalyst particles is maintained during use. The molar ratio of Group 6 to Group 8 - 10 non-noble metals ranges generally from 10: 1- 1 : 10 and preferably from 3 : 1-1 :3, In the case of a core-shell structured particle, these ratios of course apply to the metals contained in the shell. If more than one Group 6 metal is contained in the bulk catalyst particles, the ratio of the different Group 6 metals is generally not critical. The same holds when more than one Group 8 - 10 non-noble metal is applied. In the case where molybdenum and tungsten are present as Group 6 metals, the molybenum:tungsten ratio preferably lies in the range of 9: 1-1 :9. Preferably the Group 8 - 10 non-noble metal comprises nickel and/or cobalt. It is further preferred that the Group 6 metal comprises a combination of molybdenum and tungsten. Preferably, combinations of nickel/molybdenum/tungsten and cobalt/molybdenum/tungsten and nickel/cobalt/molybdenum/tungsten are used. These types of precipitates appear to be sinter-resistant. Thus, the active surface area of the precipitate is maintained during use. The metals are preferably present as oxidic compounds of the corresponding metals, or if the catalyst composition has been sulfided, sulfidic compounds of the corresponding metals.

[0090] In some optional aspects, the bulk metal hydrotreating catalysts used herein have a surface area of at least 50 m ² /g and more preferably of at least 100 m ² /g. In such aspects, it is also desired that the pore size distribution of the bulk metal hydrotreating catalysts be approximately the same as the one of conventional hydrotreating catalysts. Bulk metal hydrotreating catalysts can have a pore volume of 0.05-5 ml/g, or of 0.1-4 ml/g, or of 0.1-3 ml/g, or of 0.1-2 tag determined by nitrogen adsorption. Preferably, pores smaller than 1 nm are not present. The bulk metal hydrotreating catalysts can have a median diameter of at least 50 nm, or at least 100 nm. The bulk metal hydrotreating catalysts can have a median diameter of not more than 5000 μιτι, or not more than 3000 μιη. In an embodiment, the median particle diameter lies in the range of 0.1-50 μιη and most preferably in the range of 0.5-50 μιη.

[0091] In aspects that include hydrocracking as part of the initial hydroprocessing stage, the initial stage hydrocracking catalyst can comprise any suitable or standard hydrocracking catalyst, for example, a zeolitic base selected from zeolite Beta, zeolite X, zeolite Y, faujasite, ultrastable Y (USY), dealuminized Y (Deal Y), Mordenite, ZSM-3, ZSM-4, ZSM-18, ZSM-20, ZSM-48, and combinations thereof, which zeolitic base can advantageously be loaded with one or more active metals (e.g., either (i) a Group 8 - 10 noble metal such as platinum and/or palladium or (ii) a Group 8 - 10 non-noble metal such nickel, cobalt, iron, and combinations thereof, and a Group 6 metal such as molybdenum and/or tungsten). In this discussion, zeolitic materials are defined to include materials having a recognized zeolite framework structure, such as framework structures recognized by the International Zeolite Association. Such zeolitic materials can correspond to silicoaluminates, silicoaluminophosphates, aluminophosphates, and/or other combinations of atoms that can be used to form a zeolitic framework structure. In addition to zeolitic materials, other types of crystalline acidic support materials may also be suitable. Optionally, a zeolitic material and/or other crystalline acidic material may be mixed or bound with other metal oxides such as alumina, titania, and/or silica.

[0092] A hydrocracking process in the first stage (or otherwise under sour conditions) can be carried out at temperatures of 200°C to 450°C, hydrogen partial pressures of from 250 psig to 5000 psig (-1.8 MPag to -34.6 MPag), liquid hourly space velocities of from 0.2 h ^"1 to 10 h ^"1 , and hydrogen treat gas rates of from 35.6 m ³ /m ³ to 1781 m ³ /m ³ (-200 SCF/B to -10,000 SCF/B), Typically, in most cases, the conditions can include temperatures in the range of 300°C to 450°C, hydrogen partial pressures of from 500 psig to 2000 psig (-3.5 MPag to -13.9 MPag), liquid hourly space velocities of from 0.3 h ^"1 to 2 h ^"1 and hydrogen treat gas rates of from 213 m ³ /m ³ to 1068 m ³ /m ³ (-1200 SCF/B to -6000 SCF/B).

[0093] Optionally, a demetallization catalyst can be included as part of the initial processing stage. Conventional catalysts and conditions for demetallization can be used. In some aspects, an initial bed of demetallization catalyst can be included in a hydrotreating reactor, so that demetallization is performed under hydrotreating conditions.

Additional Second Stage Processing - Dewaxing and Hydrofinishing / Aromatic Saturation

[0094] After hydroprocessing in the first stage, the hydroprocessed effluent can be separated. In some aspects the separation can correspond to a separation that is primarily focused on separation of contaminant gases (FhS, Fb) that are generated during heteroatom removal. In some aspects, additional lower boiling portions of the hydroprocessed effluent can be separated out, such as naphtha and/or diesel boiling range portions. In such aspects, a lubricant boiling range portion (optionally including a diesel boiling range portion and/or other hydroprocessed bottoms) can be further processed by catalytic dewaxing and/or hydrofinishing or aromatic saturation.

[0095] In various aspects, catalytic dewaxing can be included as part of a second or subsequent processing stage. Preferably, the dewaxing catalysts are zeolites (and/or zeolitic crystals) that perform dewaxing primarily by isomerizing a hydrocarbon feedstock. More preferably, the catalysts are zeolites with a uni dimensional pore structure. Suitable catalysts include 10-member ring pore zeolites, such as EU-1, ZSM-35 (or ferrierite), ZSM-11, ZSM-57, NU-87, SAPO-11, and ZSM-22. Preferred materials are EU-2, EU-11, ZBM-30, ZSM-48, or ZSM-23. ZSM-48 is most preferred. Note that a zeolite having the ZSM-23 structure with a silica to alumina ratio of from 20: 1 to 40: 1 can sometimes be referred to as SSZ-32. Other zeolitic crystals that are isostructural with the above materials include Theta-1, NU-10, EU-13, KZ-1, and NU-23.

[0096] In various embodiments, the dewaxing catalysts can further include a metal hydrogenation component. The metal hydrogenation component is typically a Group 6 and/or a Group 8 - 10 metal. Preferably, the metal hydrogenation component is a Group 8 - 10 noble metal. Preferably, the metal hydrogenation component is Pt, Pd, or a mixture thereof. In an alternative preferred embodiment, the metal hydrogenation component can be a combination of a non-noble Group 8 - 10 metal with a Group 6 metal. Suitable combinations can include Ni, Co, or Fe with Mo or W, preferably Ni with Mo or W.

[0097] The metal hydrogenation component may be added to the dewaxing catalyst in any convenient manner. One technique for adding the metal hydrogenation component is by incipient wetness. For example, after combining a zeolite and a binder, the combined zeolite and binder can be extruded into catalyst particles. These catalyst particles can then be exposed to a solution containing a suitable metal precursor. Alternatively, metal can be added to the catalyst by ion exchange, where a metal precursor is added to a mixture of zeolite (or zeolite and binder) prior to extrusion.

[0098] The amount of metal in the dewaxing catalyst can be at least 0.1 wt % based on catalyst, or at least 0.15 wt %, or at least 0.2 wt %, or at least 0.25 wt %, or at least 0.3 wt %, or at least 0.5 wt % based on catalyst. The amount of metal in the catalyst can be 20 wt % or less based on catalyst, or 10 wt % or less, or 5 wt % or less, or 2.5 wt % or less, or 1 wt % or less. For aspects where the metal is Pt, Pd, another Group 8 - 10 noble metal, or a combination thereof, the amount of metal can be from 0.1 to 5 wt %, preferably from 0.1 to 2 wt %, or 0.25 to 1.8 wt %, or 0.4 to 1.5 wt %. For aspects where the metal is a combination of a non-noble Group 8 - 10 metal with a Group 6 metal, the combined amount of metal can be from 0.5 wt % to 20 wt %, or 1 wt % to 15 wt %, or 2.5 wt % to 10 wt %.

[0099] Preferably, a dewaxing catalyst can be a catalyst with a low ratio of silica, to alumina. For example, for ZSM-48, the ratio of silica to alumina in the zeolite can be less than 200: 1, or less than 110: 1, or less than 100: 1, or less than 90: 1, or less than 80: 1. In particular, the ratio of silica to alumina can be from 30: 1 to 200: 1, or 60: 1 to 110: 1, or 70: 1 to 100: 1. [00100] A dewaxing catalyst can also include a binder. In some embodiments, the dewaxing catalysts used in process according to the invention are formulated using a low surface area binder, a low surface area binder represents a binder with a surface area of 100 m ² /g or less, or 80 m ² /g or less, or 70 m ² /g or less, such as down to 40 m ² /g or still lower.

[00101] Alternatively, the binder and the zeolite particle size can be selected to provide a catalyst with a desired ratio of micropore surface area to total surface area. In dewaxing catalysts used according to the invention, the micropore surface area corresponds to surface area from the unidimensional pores of zeolites in the dewaxing catalyst. The total surface corresponds to the micropore surface area plus the external surface area. Any binder used in the catalyst will not contribute to the micropore surface area and will not significantly increase the total surface area of the catalyst. The external surface area represents the balance of the surface area of the total catalyst minus the micropore surface area. Both the binder and zeolite can contribute to the value of the external surface area. Preferably, the ratio of micropore surface area to total surface area for a dewaxing catalyst will be equal to or greater than 25%.

[00102] A zeolite (or other zeolitic material) can be combined with binder in any convenient manner. For example, a bound catalyst can be produced by starting with powders of both the zeolite and binder, combining and mulling the powders with added water to form a mixture, and then extruding the mixture to produce a bound catalyst of a desired size. Extrusion aids can also be used to modify the extrusion flow properties of the zeolite and binder mixture. The amount of framework alumina in the catalyst may range from 0.1 to 3.33 wt %, or 0.1 to 2.7 wt %, or 0.2 to 2 wt %, or 0.3 to 1 wt %.

[00103] In yet another embodiment, a binder composed of two or more metal oxides can also be used. In such an embodiment, the weight percentage of the low surface area binder is preferably greater than the weight percentage of the higher surface area binder.

[00104] Alternatively, if both metal oxides used for forming a mixed metal oxide binder have a sufficiently low surface area, the proportions of each metal oxide in the binder are less important. When two or more metal oxides are used to form a binder, the two metal oxides can be incorporated into the catalyst by any convenient method. For example, one binder can be mixed with the zeolite during formation of the zeolite powder, such as during spray drying. The spray dried zeolite/binder powder can then be mixed with the second metal oxide binder prior to extrusion. In an aspect, the dewaxing catalyst can be self-bound and does not contain a binder. Process conditions in a catalytic dewaxing zone can include a temperature of from 200 to 450°C, preferably 270 to 400°C, a hydrogen partial pressure of from 1.8 to 34.6 mPa (-250 to -5000 psi), preferably 4.8 to 20.8 mPa, a liquid hourly space velocity of from 0.2 to 10 hr ^"1 , preferably 0.5 to 3.0 hr ^"1 , and a hydrogen circulation rate of from 35.6 to 1781 m ³ /m ³ (-200 to -10,000 scf/B), preferably 178 to 890.6 m ³ /m ³ (-1000 to -5000 scf/B).

[00105] In various aspects, a hydrofinishing and/or aromatic saturation process can also be provided. The hydrofinishing and/or aromatic saturation can occur prior to dewaxing and/or after dewaxing. The hydrofinishing and/or aromatic saturation can occur either before or after fractionation. If hydrofinishing and/or aromatic saturation occurs after fractionation, the hydrofinishing can be performed on one or more portions of the fractionated product, such as being performed on one or more lubricant base stock portions. Alternatively, the entire effluent from the last hydrocracking or dewaxing process can be hydrofinished and/or undergo aromatic saturation.

[00106] In some situations, a hydrofinishing process and an aromatic saturation process can refer to a single process performed using the same catalyst. Alternatively, one type of catalyst or catalyst system can be provided to perform aromatic saturation, while a second catalyst or catalyst system can be used for hydrofinishing. Typically a hydrofinishing and/or aromatic saturation process will be performed in a separate reactor from dewaxing or hydrocracking processes for practical reasons, such as facilitating use of a lower temperature for the hydrofinishing or aromatic saturation process. However, an additional hydrofinishing reactor following a hydrocracking or dewaxing process but prior to fractionation could still be considered part of a second stage of a reaction system conceptually.

[00107] Hydrofinishing and/or aromatic saturation catalysts can include catalysts containing Group 6 metals, Group 8 - 10 metals, and mixtures thereof. In an embodiment, preferred metals include at least one metal sulfide having a strong hydrogenation function. In another embodiment, the hydrofinishing catalyst can include a Group 8 - 10 noble metal, such as Pt, Pd, or a combination thereof. The mixture of metals may also be present as bulk metal catalysts wherein the amount of metal is 30 wt. % or greater based on catalyst. Suitable metal oxide supports include low acidic oxides such as silica, alumina, silica-aluminas or titania, preferably alumina. The preferred hydrofinishing catalysts for aromatic saturation will comprise at least one metal having relatively strong hydrogenation function on a porous support. Typical support materials include amorphous or crystalline oxide materials such as alumina, silica, and silica-alumina. The support materials may also be modified, such as by halogenation, or in particular fluorination. The metal content of the catalyst is often as high as 20 weight percent for non-noble metals. In an embodiment, a preferred hydrofinishing catalyst can include a crystalline material belonging to the M41 S class or family of catalysts. The M41 S family of catalysts are mesoporous materials having high silica content. Examples include MCM-41, MCM-48 and MCM-50. A preferred member of this class is MCM-41. If separate catalysts are used for aromatic saturation and hydrofinishing, an aromatic saturation catalyst can be selected based on activity and/or selectivity for aromatic saturation, while a hydrofinishing catalyst can be selected based on activity for improving product specifications, such as product color and polynuclear aromatic reduction.

[00108] Hydrofinishing conditions can include temperatures from 125°C to 425°C, preferably 180°C to 280°C, total pressures from 500 psig (-3.4 MPag) to 3000 psig (-20.7 MPag), preferably 1500 psig (-10.3 MPag) to 2500 psig (-17.2 MPag), and liquid hourly space velocity (LHSV) from 0.1 hr ^"1 to 5 hr ^"1 , preferably 0.5 hr ^"1 to 1.5 hr ¹ .

[00109] A second fractionation or separation can be performed at one or more locations after a second or subsequent stage. In some aspects, a fractionation can be performed after hydrocracking in the second stage in the presence of the USY catalyst under sweet conditions. At least a lubricant boiling range portion of the second stage hydrocracking effluent can then be sent to a dewaxing and/or hydrofinishing reactor for further processing. In some aspects, hydrocracking and dewaxing can be performed prior to a second fractionation. In some aspects, hydrocracking, dewaxing, and aromatic saturation can be performed prior to a second fractionation. Optionally, aromatic saturation and/or hydrofinishing can be performed before a second fractionation, after a second fractionation, or both before and after.

Example 1 - Block Processing of Light Neutral and Heavy Neutral

[00110] The following is a prophetic example. A processing configuration similar to the configurations shown in FIGS. 1 to 3 is used to process a feedstock to form a light neutral base stock product and a heavy neutral base stock product. The full range feed is processed in the first (sour) processing stage. Fractionation is then used to form separate hydroprocessed feeds for light neutral base stock production and heavy neutral base stock production. After fractionation, the feed for light neutral base stock production has a viscosity index of 85 and the feed for heavy neutral base stock production has a viscosity index of 90. Blocked operation is then used to process the feeds. The conversion in the second stage hydrocracking reactor for the light neutral feed is sufficient to produce a light neutral base stock product with a viscosity index of 135 and a viscosity of roughly 4.0 cSt. The amount of conversion for the light neutral feed in the second stage hydrocracking reactor is roughly 60 wt% relative to 370°C. The conversion in the second stage hydrocracking reactor for the heavy neutral feed is sufficient to produce a heavy neutral base stock product with a viscosity index of 95 and a viscosity of roughly 11 cSt. The amount of conversion for the heavy neutral feed in the second stage hydrocracking reactor is roughly 10 wt% relative to 370°C. Example 2 - Reactor Temperature Management During Heavy Neutral Processing

[00111] The following is a prophetic example. A processing configuration similar to FIG. 2 can be used to perform second stage processing for production of a heavy neutral feedstock, such as production of a heavy neutral feedstock as part of block operation of the processing configuration for production of a plurality of lubricant base stocks. In this example, at least one initial catalyst bed in the first reactor stage (shown as 110 in FIG. 2) corresponds to a bed of aromatic saturation catalyst. Additionally, at least one subsequent catalyst bed in the first reactor stage corresponds to a bed of hydrocracking catalyst, such as a hydrocracking catalyst including Pt supported on a USY zeolite. Thus, the first reactor stage corresponds to a hydrocracking stage. In this example, at least one initial catalyst bed in the second reactor (shown as 120 in FIG. 2) corresponds to a bed of dewaxing catalyst. Thus, the second reactor stage corresponds to a dewaxing stage. Optionally, at least one subsequent catalyst bed in the second reactor can correspond to an aromatic saturation catalyst. It is noted that references to a catalyst bed in this example are understood to include configurations where a bed is only partially filled with a type of catalyst and/or where a single reactor bed for holding catalyst contains multiple layers (or stacked beds) of different catalyst types. The third reactor (shown as 140 in FIG. 2) can include one or more beds of aromatic saturation catalyst.

[00112] In this example, at the beginning of processing of the heavy neutral feed, the temperature required by the first (hydrocracking) reactor may be low. The initial low temperature can be due in part to needing only a limited amount of viscosity index uplift to meet a desired target for heavy neutral production and/or due in part to a relatively high activity for the catalyst(s) in the reactor. As an example, a start of run temperature for the inlet to the first reactor can be 560°F (293°C). Based on the reactions in the reactor, the start of run temperature for the exit of the first reactor can be 585°F (307°C). This temperature can be below the desired temperature for performing dewaxing in order to achieve a desired target for cold flow properties for the final heavy neutral product. For example, the start of run temperature for the inlet to the second reactor can be 600°F (316°C).

[00113] After a period of time, processing of the heavy neutral feed can result in deactivation of the catalysts in the various reactors. This aging can be due to coke formation and/or any other typical reason that a hydroprocessing catalyst has a reduction in activity due to exposure to a feed under hydroprocessing conditions. To compensate for catalyst aging, the temperature of the first reactor can be increased so that the desired amount of viscosity index uplift is still achieved, while the temperature of the second reactor can be increased so that the desired amount of improvement in cold flow properties is achieved. Because dewaxing catalysts often age more slowly than hydrocracking catalysts, the amount of temperature increase required for the first reactor may be greater than the amount for the second reactor. As a result, by the end of the processing run, the inlet temperature for the first reactor can be 575°C. At this higher temperature, more reaction can occur, leading to a greater disparity between the temperatures for the first reactor inlet and the first reactor outlet. The end of run temperature for the first reactor outlet can be 640°F (338°C). Optionally, a portion of this greater disparity can also correspond to removing quench streams between the initial aromatic saturation catalyst bed(s) and the subsequent hydrocracking catalyst bed(s). By contrast, the amount of catalyst aging for the dewaxing catalyst can result in a more modest temperature increase, so that the reactor inlet temperature for the second reactor at the end of the run can be 630°F (332°C).

[00114] Based on a comparison of the difference between the first reactor outlet temperatures and the second reactor inlet temperatures, the temperature profile between the first and second reactors is flipped between the start of the processing run and the end of the processing run. At the start of the processing run, the first reactor outlet temperature is colder than the second reactor inlet temperature by 9°C. At the end of the processing run, the first reactor outlet temperature is warmer than the second reactor inlet temperature by 6°C. The heated hydrogen lines 281 and/or 282 can be used to facilitate achieving these desired temperature differentials. For example, at the start of the processing run, additional heated hydrogen can be delivered to the second reactor to provide the additional temperature needed to achieve the desired start of run temperature for dewaxing. Additionally or alternately, heat exchangers could be used to provide this temperature increase. Over time, the amount of heated hydrogen delivered via heated hydrogen line 282 can be reduced, until at some point during the processing run the inlet temperature for the dewaxing reactor falls below the exit temperature for the hydrocracking reactor. As the processing run continues, heated hydrogen line 281 can optionally be used to provide additional heat for the first (hydrocracking) reactor. Additionally or alternately, additional heating of the feed can be used to achieve the temperature increases for the first reactor that are needed to offset catalyst aging.

[00115] A similar switch in the order reactor temperatures could also occur, for example, during second stage processing of a feed for brightstock production. In this additional example, the same type of catalyst systems described above can be used. The start of run temperatures for the hydrocracking reactor inlet / hydrocracking reactor outlet can be 560°F (293°C) / 585°F (307°C), which are similar to the corresponding temperatures for the heavy neutral processing example. Due in part to a higher amount of desired viscosity index uplift for the final product, the end of run temperatures for the hydrocracking reactor inlet / outlet can be 610°F (321°C) / 700°F (371°C). For dewaxing, the start of run inlet temperature can be 650°F (343°C), while the end of run inlet temperature can be 690°F (366°C). Thus, for this example, the outlet of the hydrocracking reactor at start of run is colder than the dewaxing inlet by more than 30°C, while the outlet of the hydrocracking reactor is warmer than the dewaxing inlet at end of run by 5°C.

Additional Embodiments

[00116] Embodiment 1. A method for producing lubricant boiling range product using blocked operation, comprising: fractionating a hydroprocessed feedstock to form at least a first lubricant boiling range fraction comprising a 343°C+ portion and a second lubricant boiling range fraction having a T10 distillation point of at least 343°C and a kinematic viscosity at 100°C of 6.0 cSt or more, the 343°C+ portion of the first lubricant boiling range fraction having a kinematic viscosity at 100°C of 1.5 cSt to 6.0 cSt, the second lubricant boiling range fraction optionally having a viscosity index that is greater than the viscosity index of the first lubricant boiling range fraction; hydrocracking at least a portion of the first lubricant boiling range fraction in the presence of hydrocracking catalyst under first hydrocracking conditions comprising a first hydrocracking inlet temperature and a first hydrocracking outlet temperature in a first reactor to form a first hydrocracked effluent, the first hydrocracking conditions comprising 10 wt% to 80 wt% conversion relative to 370°C of the at least a portion of the first lubricant boiling range fraction; dewaxing at least a portion of the first hydrocracked effluent under first catalytic dewaxing conditions in a second reactor to form a first dewaxed effluent; hydrocracking at least a portion of the second lubricant boiling range fraction in the presence of the hydrocracking catalyst under second hydrocracking conditions in the first reactor to form a second hydrocracked effluent, the second hydrocracking conditions comprising 1 wt% to 25 wt% conversion relative to 370°C of the at least a portion of the second lubricant boiling range fraction, the second hydrocracking conditions comprising a second hydrocracking inlet temperature and a second hydrocracking outlet temperature, the conversion relative to 370°C for the first hydrocracking conditions being at least 10 wt% greater (or at least 20 wt% greater, or at least 30 wt% greater) than the conversion relative to 370°C for the second hydrocracking conditions; dewaxing at least a portion of the second hydrocracked effluent under second catalytic dewaxing conditions in the second reactor to form a second dewaxed effluent; fractionating at least a portion of the first dewaxed effluent to form at least a first fuels boiling range product and a first lubricant boiling range product; and fractionating at least a portion of the second dewaxed effluent to form at least a second fuels boiling range product and a second lubricant boiling range product, a viscosity index of the second lubricant boiling range product being lower than a viscosity index of the first lubricant boiling range product by at least 5 (or at least 15, or at least 25). [00117] Embodiment 2. The method of Embodiment 1, further comprising hydroprocessing a feedstock under hydroprocessing conditions to form the hydroprocessed feedstock.

[00118] Embodiment 3. A method for producing lubricant boiling range product using blocked operation, comprising: fractionating a feedstock to form at least a first lubricant boiling range fraction comprising a 343°C+ portion and a second lubricant boiling range fraction having a T10 distillation point of at least 343°C and a kinematic viscosity at 100°C of 6.0 cSt or more, the 343°C+ portion having a kinematic viscosity at 100°C of 1.5 cSt to 6.0 cSt, the second lubricant boiling range fraction optionally having a viscosity index that is greater than the viscosity index of the first lubricant boiling range fraction; hydroprocessing at least a portion of the first lubricant boiling range fraction under first hydroprocessing conditions to form a first hydroprocessed effluent; hydrocracking at least a portion of the first hydroprocessed effluent in the presence of hydrocracking catalyst under first hydrocracking conditions in a first reactor to form a first hydrocracked effluent, the first hydroprocessing conditions and the first hydrocracking conditions comprising a combined conversion of the first lubricant boiling range fraction of 40 wt% to 80 wt% relative to 370°C; dewaxing at least a portion of the first hydrocracked effluent under first catalytic dewaxing conditions in a second reactor to form a first dewaxed effluent; hydroprocessing at least a portion of the second lubricant boiling range fraction under second hydroprocessing conditions to form a second hydroprocessed effluent; hydrocracking at least a portion of the second hydroprocessed effluent in the presence of the hydrocracking catalyst under second hydrocracking conditions in the first reactor to form a second hydrocracked effluent, the second hydroprocessing conditions and the second hydrocracking conditions comprising a combined conversion of the second lubricant boiling range fraction of 20 wt% to 60 wt% relative to 370°C; dewaxing at least a portion of the second hydrocracked effluent under second catalytic dewaxing conditions in the second reactor to form a second dewaxed effluent; fractionating at least a portion of the first dewaxed effluent to form at least a first fuels boiling range product and a first lubricant boiling range product; and fractionating at least a portion of the second dewaxed effluent to form at least a second fuels boiling range product and a second lubricant boiling range product, a viscosity index of the second lubricant boiling range product being lower than a viscosity index of the first lubricant boiling range product by at least 5 (or at least 15, or at least 25).

[00119] Embodiment 4. The method of any of the above embodiments, wherein the second catalytic dewaxing conditions comprise a second dewaxing inlet temperature that is greater than the second hydrocracking outlet temperature (or at least 5°C greater, or at least 10°C greater, or at least 20°C, or at least 30°C), or wherein the first catalytic dewaxing conditions comprise a first dewaxing inlet temperature that is less than the first hydrocracking outlet temperature (or at least 5°C less, or at least 10°C less, or at least 20°C less), or a combination thereof.

[00120] Embodiment 5. The method of any of the above embodiments, wherein the second catalytic dewaxing conditions comprise introducing a heated hydrogen-containing stream into the second reactor.

[00121] Embodiment 6. The method of any of the above embodiments, wherein one or more of the hydroprocessed feedstock, the first lubricant boiling range fraction, and the second boiling range fraction comprise 100 wppm or less of sulfur; or wherein the hydrocracking catalyst comprises 0.1 wt% to 5.0 wt% of a noble metal supported on the hydrocracking catalyst; or wherein the hydrocracking catalyst comprises USY zeolite having a unit cell size of 24.30 A or less, a silica to alumina ratio of at least 50, and an Alpha value of 20 or less; or a combination thereof.

[00122] Embodiment 7. The method of any of the above embodiments, wherein fractionating the hydroprocessed feedstock further comprising forming a fuels boiling range fraction.

[00123] Embodiment 8. The method of any of the above embodiments, i) further comprising storing the at least a portion of the first lubricant boiling range fraction prior to the hydrocracking of the at least a portion of the first lubricant boiling range fraction, ii) further comprising storing the at least a portion of the second lubricant boiling range fraction prior to the hydrocracking of the at least a portion of the second lubricant boiling range fraction, or iii) a combination of i) and ii).

[00124] Embodiment 9. The method of any of the above embodiments, wherein the first reactor further comprises an aromatic saturation catalyst, wherein the second reactor further comprises an aromatic saturation catalyst, or a combination thereof.

[00125] Embodiment 10. The method of any of the above embodiments, wherein the first lubricant boiling range product comprises a viscosity index of at least 125 (or at least 130, or at least 135); or wherein the second lubricant boiling range product comprises a viscosity index of at least 80 (or at least 85, or at least 90); or wherein the viscosity index of the second lubricant boiling range product is lower than the viscosity index of the first lubricant boiling range product by at least 15 (or at least 25); or a combination thereof.

[00126] Embodiment 11. The method of any of the above embodiments, wherein the first dewaxing conditions are substantially similar to the second dewaxing conditions; or wherein the first hydrocracking inlet temperature is greater than the second hydrocracking inlet temperature by at least 10°C (or at least 15°C, or at least 20°C); or a combination thereof.

[00127] Embodiment 12. The method of any of the above embodiments, further comprising: exposing at least a portion of the first dewaxed effluent to an aromatic saturation catalyst in a third reactor under first aromatic saturation conditions to form a first saturated product comprising the first lubricant boiling range product, the first lubricant boiling range product having an aromatics content of 2.0 wt% or less; and exposing at least a portion of the second dewaxed effluent to the aromatic saturation catalyst in the third reactor under second aromatic saturation conditions to form a second saturated product comprising the second lubricant boiling range product, the second lubricant boiling range product having an aromatics content of 2.0 wt% or less, the first aromatic saturation conditions optionally being substantially similar to the second aromatic saturation conditions, the second reactor optionally further comprising a second aromatic saturation catalyst, the at least a portion of the first hydrocracked effluent contacting at least a portion of the second aromatic saturation catalyst prior to being exposed to the dewaxing catalyst.

[00128] Embodiment 13. A multi-reactor reaction system, comprising: a first reactor comprising a first gas inlet, hydrocracking reactor inlet, a hydrocracking reactor outlet, and a hydrocracking catalyst comprising 0.1 wt% to 5.0 wt% of a Group 8 - 10 noble metal supported on the hydrocracking catalyst; a second reactor comprising a second gas inlet, a dewaxing reactor inlet, a dewaxing reactor outlet, and a dewaxing catalyst, the dewaxing reactor inlet being in fluid communication with the hydrocracking reactor outlet; a third reactor comprising an aromatic saturation inlet, an aromatic saturation outlet, and a first aromatic saturation catalyst, the aromatic saturation inlet being in fluid communication with the dewaxing reactor outlet; and a heater comprising a feed heater flow path and a hydrogen heater flow path, the feed heater flow path being in fluid communication with the hydrocracking reactor inlet, the hydrogen heater flow path being in fluid communication with the first gas inlet and the second gas inlet, wherein optionally at least a portion of a second aromatic saturation catalyst is located upstream from the dewaxing catalyst relative to a direction of flow in the second reactor.

[00129] Embodiment 14. The system of Embodiment 13, wherein the third reactor further comprises a third gas inlet in fluid communication with the hydrogen heater flow path, or wherein the hydrocracking reactor inlet comprises the first gas inlet, or wherein the second gas inlet is in selective fluid communication with the heated hydrogen flow path, or a combination thereof.

[00130] Embodiment 15. The system of Embodiment 13 or 14, the system further comprising a first storage tank and a second storage tank, the first storage tank and the second storage tank being in selective fluid communication with the feed heater flow path, the first storage tank comprising a first lubricant boiling range feed comprising a 343°C+ portion, the 343°C+ portion of the first lubricant boiling range feed having a kinematic viscosity at 100°C of 1.5 cSt to 6.0 cSt, the second storage tank comprising a second lubricant boiling range feed having a T10 distillation point of at least 343°C and a kinematic viscosity at 100°C of 6.0 cSt or more, the second lubricant boiling range feed optionally having a viscosity index that is greater than the viscosity index of the first lubricant boiling range feed.

[00131] Embodiment 16. A method for producing a lubricant boiling range product, comprising: hydrocracking a lubricant boiling range fraction in the presence of hydrocracking catalyst under first hydrocracking conditions comprising a first hydrocracking inlet temperature and a first hydrocracking outlet temperature in a first reactor to form a first hydrocracked effluent, the first hydrocracking conditions comprising a first amount of conversion relative to 370°C of the at least a portion of the lubricant boiling range fraction; dewaxing at least a portion of the first hydrocracked effluent under first catalytic dewaxing conditions comprising a first dewaxing inlet temperature in a second reactor to form a first dewaxed effluent, the first dewaxing inlet temperature being greater than the first hydrocracking outlet temperature by at least 3°C (or at least 5°C, or at least 8°C, or at least 10°C); modifying the conditions for hydrocracking while performing hydrocracking of the lubricant boiling range fraction; hydrocracking the lubricant boiling range fraction in the presence of the hydrocracking catalyst under modified hydrocracking conditions comprising a modified hydrocracking inlet temperature and a modified hydrocracking outlet temperature in the first reactor to form a second hydrocracked effluent, the modified hydrocracking conditions comprising a second amount of conversion relative to 370°C of the at least a portion of the lubricant boiling range fraction, the second amount of conversion relative to 370°C being different from the first amount of conversion relative to 370°C by 5 wt% or less; dewaxing at least a portion of the second hydrocracked effluent under second catalytic dewaxing conditions comprising a second dewaxing inlet temperature in the second reactor to form a second dewaxed effluent, the second dewaxing inlet temperature being less than the modified hydrocracking outlet temperature by at least 3°C (or at least 5°C, or at least 8°C, or at least 10°C); fractionating at least a portion of the first dewaxed effluent to form at least a first fuels boiling range product and a first lubricant boiling range product; and fractionating at least a portion of the second dewaxed effluent to form at least a second fuels boiling range product and a second lubricant boiling range product, a viscosity index of the second lubricant boiling range product being different than a viscosity index of the first lubricant boiling range product by 5 or less (or 3 or less, or 1 or less).

[00132] Embodiment 17. The method of Embodiment 16, wherein the lubricant boiling range fraction has a T10 distillation point of at least 343°C and a kinematic viscosity at 100°C of 6.0 cSt or more; or wherein the lubricant boiling range fraction has a T10 distillation point of at least 371°C and a kinematic viscosity at 100°C of 15 cSt or more; or wherein the lubricant boiling range fraction comprises a 343°C+ portion, the 343°C+ portion having a kinematic viscosity at 100°C of 1.5 cSt to 6.0 cSt.

[00133] Embodiment 18. The method of Embodiment 16 or 17, wherein the first catalytic dewaxing conditions comprise introducing a heated hydrogen-containing stream into the second reactor.

[00134] Embodiment 19. The method of any of Embodiments 16 to 18, further comprising hydrofinishing the at least a portion of the first dewaxed effluent prior to fractionation, after fractionation, or a combination thereof, the hydrofinishing comprising exposing at least a portion of the first dewaxed effluent to an aromatic saturation catalyst in a third reactor under first aromatic saturation conditions to form a first saturated product comprising the first lubricant boiling range product, the first lubricant boiling range product having an aromatics content of 2.0 wt% or less.

[00135] Embodiment 20. The method of any of Embodiments 16 to 19, further comprising modifying the conditions for dewaxing while performing dewaxing of hydrocracked effluent produced during the modification of the conditions for hydrocracking, the second dewaxing conditions comprise modified dewaxing conditions, the second dewaxing inlet temperature comprising a modified dewaxing inlet temperature.

[00136] Embodiment 21. The method of any of Embodiments 16 to 20, further comprising modifying the conditions for dewaxing i) while performing dewaxing of the at least a portion of the first hydrocracked effluent, ii) while performing dewaxing of the at least a portion of the second hydrocracked effluent, or iii) a combination of i) and ii).

[00137] Embodiment 22. The method of any of Embodiments 16 to 21, wherein at least one of the hydroprocessed feedstock and the lubricant boiling range fraction comprise 100 wppm or less of sulfur; or wherein the hydrocracking catalyst comprises 0.1 wt% to 5.0 wt% of a noble metal supported on the hydrocracking catalyst; or wherein the hydrocracking catalyst comprises USY zeolite having a unit cell size of 24.30 A or less, a silica to alumina ratio of at least 50, and an Alpha value of 20 or less; or a combination thereof.

[00138] When numerical lower limits and numerical upper limits are listed herein, ranges from any lower limit to any upper limit are contemplated. While the illustrative embodiments of the invention have been described with particularity, it will be understood that various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the spirit and scope of the invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the examples and descriptions set forth herein but rather that the claims be construed as encompassing all the features of patentable novelty which reside in the present invention, including all features which would be treated as equivalents thereof by those skilled in the art to which the invention pertains.

[00139] The present invention has been described above with reference to numerous embodiments and specific examples. Many variations will suggest themselves to those skilled in this art in light of the above detailed description. All such obvious variations are within the full intended scope of the appended claims.