Hydroprocessing catalysts and methods for making thereof

A method to reduce deposit of at least a metal contaminant from a heavy oil feedstock in a system to upgrade the heavy oil feedstock, wherein the system to upgrade the heavy oil feedstock further comprises a catalyst feed system, the method comprising:

• (a) providing a fresh slurry catalyst having at least one metal selected from the group consisting of Group VIB, Group VIII and Group IIB and comprising a plurality of particles dispersed as a slurry in a hydrocarbon medium at a total metal concentration of 500 wppm to 3 wt. % of metals to heavy oil feedstock;
• and
• (b) providing a deoiled spent catalyst comprising a plurality of particles dispersed in a hydrocarbon medium as a slurry, wherein the deoiled spent catalyst has less than 80% but more than 10% of the original catalytic activity;
• and
• (c) combining the fresh slurry catalyst with the deoiled spent catalyst to form a total amount of slurry catalyst to the heavy oil upgrade system, wherein the dry weight ratio of fresh slurry catalyst to deoiled spent catalyst ranges from 1:5 to 5:1 and
• (d) contacting the heavy oil feedstock with the total amount of slurry catalyst to the heavy oil upgrade system under hydrocracking conditions to convert at least a portion of the heavy oil feedstock to lower boiling hydrocarbons, forming upgraded products;
• and
• wherein the deoiled spent catalyst is present in the catalyst feed system in an amount sufficient to reduce the deposit of the metal contaminant in the system to upgrade the heavy oil feedstock of at least 5% compared to an upgrade system without the deoiled spent catalyst.