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Bitumen residues in the oil sand tailings can be a threat to the environmentthat separating them from tailings before disposal is crucial. However, lowbitumen concentration in the tailings slurry and the complex transportcharacteristics of the four-phase mixture make the process difficult. Thisstudy establishes an Eulerian-Eulerian CFD model for an industrial-scale oilsand tailings pipeline. A comprehensive sensitivity analysis was conducted onthe selection of carrier-solid and solid-bitumen drag models. The combinationof small and large particle sizes (i.e., 75 & 700 um) and bitumen droplet size(i.e., 400 um) provided good agreement with field data in velocity profiles andpressure drop. The validated model was subsequently extended to investigate theinfluence of the secondary phase (i.e., bitumen droplets and bubbles) on flowcharacteristics in a tailing pipeline. The investigation covered a range ofbitumen droplet size (100-400 um), bitumen fraction (0.0025-0.1), bubble size(5-1000 um), and bubble fraction (0.0025-0.3) and their influences on thevelocity, solids, and bitumen distribution are revealed. For an optimum bubblesize of 500 um, a maximum recovery of 59% from the top 50 % and 83 % from thetop 75 % of the pipe cross-section was obtained. The present study demonstratesthe preferential distribution of bitumen and provides valuable insight onbitumen recovery from an industrial-scale tailings pipeline.

Computational fluid dynamics investigation of bitumen residues in oil sands tailings transport in an industrial horizontal pipe