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This paper presents the results of a CFD evaluation on the effectiveness of perforated plate baffles for improving flow and separation performance in a FWKO separator. Using the multiphase model coupled with turbulent interaction, a full scale 3D simulation on two FWKO configurations indicated that with installation of the perforated plate baffles, the short circuiting and recirculation flow in the vessel was reduced. As a result, the mean residence time increased from 630 seconds to 980 seconds for the water phase, and from 520 seconds to 745 seconds for the bitumen phase. Accordingly, the volumetric utilization for the bitumen phase was increased from 46% without the baffles to 66% with the baffles, which corresponds to a 43% improvement. Water phase volumetric utilization was increased from 57% without the baffles to 89% with the baffles, which was increased by 55%. Therefore, an overall 50% improvement on the liquid phase was achieved due to the introduction of the specially engineered perforated plate baffles. Introduction and Background Performance of the FWKO separators can be greatly improved by introducing appropriate internals into the vessels. Available internals include the Porta-Test RevolutionTM inlet device, PerformaxTM packing, perforated plate baffles, and other flow modification components. The revolution tube and perforated baffles were used to enhance the pre-separation and improve the flow distribution in the FWKO vessels used for the diluted bitumen treatment. A good understanding of the flow and separation behaviors within the separator is crucial for identification of design limitations and further design improvements [1]. With the development of computer and numerical methods in the last two decades, Computational Fluid Dynamics (CFD) provides a good option to simulate the complex flow and separation processes within the vessel [2]. The objective of this study was to determine the improved performance of the FWKO from introducing two specially engineered perforated plate baffles. The flow and separation behaviors in the vessel with and without perforated plate baffles were investigated numerically using the CFD approach. DESCRIPTION OF FWKO VESSEL Vessel Configuration Figure 1 schematically shows configuration of the FWKO separator. It was a horizontal vessel with an outside diameter of 5791.2 mm (19 feet) and seam to seam length of 19812 mm (65 feet). To enhance the degassing and pre-separation performances, Porta-Test RevolutionTM tubes were used as the inlet device. After bulk separation in the revolution tubes, the gas exits from top opening of the revolution tubes and the liquid phase flows out of the bottom opening of the revolution tube device. The pre-separated gas and the liquid streams then flow longitudinally in the vessel. To improve the flow distribution downstream the revolution tubes, two perforated plates with specifically designed percent open area and hole diameters on a tri-pitch pattern. The normal liquid level was maintained at 4319 mm (14.17 feet) by the level control device, and the interface level was kept at 2858 mm (9.38 feet) by an interface control system.

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