Numerical study of a hydrocyclone performance for oil-sand separation

Abstract

The oil industry faces significant challenges in ensuring efficient oil–sand separation, a critical process to preserve crude quality, reduce operating costs, and comply with environmental regulations. Under increasing global crude demand and intensified scrutiny on sustainability, optimizing separation operations has become a strategic priority. Improved separation efficiency reduces waste, enhances resource recovery, and supports the Sustainable Development Goals, particularly SDG 9 (Industry, Innovation and Infrastructure) and SDG 12 (Responsible Consumption and Production). This study assesses the performance of a hydrocyclone for oil–sand separation through computational fluid dynamics (CFD) simulations in ANSYS Fluent. The Rietema correlation is incorporated as the basis for the analysis, focusing on key parameters that govern separation performance, including the viscosity and density of the bitumen–sand mixture and the sand particle size distribution. These factors alter the internal hydrodynamics of the device (flow patterns, pressure field, and particle behavior), directly impacting separation efficiency. The main objective was to model and optimize the internal flow structure to maximize oil recovery while minimizing residual sand at the outlet. The numerical results indicate that implementing the Rietema correlation contributes to improved separation efficiency, increasing oil recovery, reducing sand carryover, and enhancing the operational reliability of the process.