Hydroconversion multi-metallic catalyst and method for making thereof

A process for forming a bulk hydroprocessing catalyst with minimal amount of metals to waste treatment, the method comprising:

• co-precipitating at reaction conditions at least one of a Group VIB metal precursor feed and at least a Promoter metal precursor feed selected from Group VIII, Group IIB, Group IIA, Group IVA and combinations thereof, to form a mixture comprising a catalyst precursor, wherein the reaction conditions comprise a temperature between 25-350° C. and a pressure between 0 to 3000 psig and a pH of 0-12;
• isolating the catalyst precursor from the mixture, forming a supernatant containing at least a Promoter metal residual and at least a Group VIB metal residual in an amount of at least 10 mole % of the metal precursor feeds;
• treating the supernatant by any of chemical precipitation, ion exchange, electro-coagulation, and combinations thereof to generate at least a metal precursor feed and a first effluent stream containing less than 50 mole % of metal ions in at least one of the metal residuals;
• treating the first effluent stream to recover at least 80 mol % of the metal ions in the first effluent stream to form at least a metal precursor feed;
• recycling the at least a metal precursor feed formed by treating the first effluent stream to the co-precipitating step;
• and
• sulfiding the catalyst precursor forming the bulk catalyst,
• wherein an effluent stream from the process to waste treatment contains less than 50 ppm metal ions.