CA2848432A1

CA2848432A1 - Bitumen recovery from in-line tailings flow based on flow profile characteristics

Info

Publication number: CA2848432A1
Application number: CA2848432A
Authority: CA
Inventors: Marek J. Dominski
Original assignee: Suncor Energy Inc
Current assignee: Suncor Energy Inc
Priority date: 2014-04-03
Filing date: 2014-04-03
Publication date: 2015-10-03
Anticipated expiration: 2034-04-03
Also published as: CA2848432C

Abstract

Recovering bitumen from an in-line tailings flow can include determining flow profile characteristics of the in-line tailings flow; based on the flow profile characteristics, identifying an interface between a bitumen-rich flow component of the in-line tailings flow and an underlying water-rich flow component; and positioning a flow redirection device in accordance with the interface in order to redirect the bitumen-rich flow component away from the water-rich flow component. The flow profile characteristics can include a velocity profile. The flow redirection device can include a skimmer blade.

Description

BITUMEN RECOVERY FROM IN-LINE TAILINGS FLOW BASED ON FLOW PROFILE
CHARACTERISTICS
FIELD
[0001] The technical field generally relates to tailings treatment and more particularly to recovering bitumen from an in-line tailings flow.
BACKGROUND

[0002] Various industries generate tailings. Extraction operations can extract valuable materials from ore using water-based extraction methods, which typically result in aqueous tailings streams that include water, solid particles and some residual amount of the valuable materials.

[0003] For example, bitumen extraction operations extract bitumen from oil sands ore and produce tailings streams that include water, solid particles including coarse and fine mineral particles, and some residual bitumen. Extraction tailings can be pipelined from an extraction plant to tailings containment areas where the tailings can settle and can be further treated in dewatering and reclamation operations.

[0004] Residual compounds, such as bitumen, can be recovered from tailings.
However, there are various challenges related to the recovery of residual valuable materials, such as bitumen, from tailings.
SUMMARY

[0005] In some implementations, there is provided a method for recovering bitumen from an in-line tailings flow, the method comprising: determining flow profile characteristics of the in-line tailings flow; based on the flow profile characteristics, identifying an interface between a bitumen-rich flow component of the in-line tailings flow and an underlying water-rich flow component; and positioning a flow redirection device in accordance with the interface in order to redirect the bitumen-rich flow component away from the water-rich flow component.

[0006] In some implementations, the flow profile characteristics comprise a velocity profile.

[0007] In some implementations, the bitumen-rich flow component that is recovered has a bitumen content of at least one order of magnitude greater than a bitumen content of the in-line tailings flow.

[0008] In some implementations, the flow redirection device comprises a skimmer blade having a lower plate, and the lower plate is located at or near the interface between the bitumen-rich flow component and the water-rich flow component.

[0009] In some implementations, the flow redirection device is located above the interface to promote a higher bitumen concentration in the bitumen-rich flow component.

[00010] In some implementations, the flow redirection device is located below the interface to promote a higher bitumen recovery from the in-line tailings flow.

[00011] In some implementations, the flow redirection device is provided at a fixed position based on the interface.

[00012] In some implementations, the flow redirection device is configured so as to be adjustable between different positions.

[00013] In some implementations, the process also includes supplying the bitumen-rich flow component to a froth treatment operation or a primary extraction operation, to recover bitumen therefrom.

[00014] In some implementations, there is provided a system for recovering bitumen from an in-line tailings flow, the system comprising: a main pipe for supplying the in-line tailings flow; a branch pipe in fluid communication with main pipe; a flow profiler for determining flow profile characteristics of the in-line tailings flow and, based on the flow profile characteristics, identifying an interface between a bitumen-rich flow component of the in-line tailings flow and an underlying bitumen-poor tailings flow component; and a flow redirection device extending into the main pipe and located in accordance with the interface in order to redirect the bitumen-rich flow component into the branch pipe.

[00015] In some implementations, the flow profiler is configured to determine a velocity profile of the in-line tailings flow.

[00016] In some implementations, the flow redirection device comprises a skimmer blade.

[00017] In some implementations, the skimmer blade comprises: a first plate fixed to the main pipe and extending downwardly into the in-line tailings flow, and a second plate extending from a lower end of the first plate in an upstream direction, the first and second plates defining with an opposed wall of the main pipe a conduit for transferring the bitumen-rich flow component from the main pipe to the branch pipe.

[00018] In some implementations, the second plate is substantially parallel with the opposed wall of the main pipe.

[00019] In some implementations, the second plate is at or near the interface between the bitumen-rich flow component and the bitumen-poor tailings flow component.

[00020] In some implementations, there is provided a method for extracting bitumen from an oil sands ore, comprising: separating an oil sands ore into a bitumen product stream and a tailings stream comprising water, solid particles and dispersed residual bitumen; supplying the tailings stream toward a tailings containment area via pipeline to induce a pressure drop and form an in-line tailings flow having a reduced hydraulic pressure; determining flow profile characteristics of the in-line tailings flow; based on the flow profile characteristics, identifying an interface between a bitumen-rich flow component of the in-line tailings flow and an underlying water-rich flow component; and positioning a flow redirection device in accordance with the interface in order to redirect the bitumen-rich flow component away from the water-rich flow component.

[00021] In some implementations, there is provided a method recovering bitumen from tailings, comprising: producing a tailings stream from a bitumen extraction operation, the tailings stream comprising a dispersed mixture of bitumen, water and solids;
piping the tailings stream to induce a pressure drop sufficient to cause separation of the tailings stream into a bitumen-rich flow component and a water-rich flow component;
determining a velocity profile of the tailings stream to identify a location of the bitumen-rich flow component within the tailings stream; based on the location of the bitumen-rich flow component, positioning a flow redirection device in the tailings stream to redirect the bitumen-rich flow component away from the water-rich flow component.

[00022] In some implementations, there is provided a use of a flow velocity profiler for identifying a location within an oil sands tailings pipeline to position an in-line bitumen skimmer. In some implementations, the location is an interface between a bitumen-rich flow component and a water-rich flow component. In some implementations, the in-line bitumen skimmer comprises a fixed skimmer blade positioned at the interface.

[00023] In some implementations, there is provided a method for recovering a water-immiscible material from an in-line tailings flow, the method comprising:
determining flow profile characteristics of the in-line tailings flow; based on the flow profile characteristics, identifying an interface between a water-immiscible flow component and a water flow component of the in-line tailings flow; and positioning a flow redirection device in accordance with the interface in order to redirect the water-immiscible flow component away from the remainder of the in-line tailings flow.

[00024] In some implementations, there is provided a method for recovering a low-density material from an in-line tailings flow, the low-density material having a lower density that water, the method comprising: determining flow profile characteristics of the in-line tailings flow; based on the flow profile characteristics, identifying an interface between a low-density flow component and an overlying a water-rich flow component of the in-line tailings flow; and positioning a flow redirection device in accordance with the interface in order to redirect the low-density flow component away from the water-rich flow component.

[00025] In some implementations, there is provided a method for recovering a water-immiscible material from an in-line aqueous suspension flow, the method comprising:
determining flow profile characteristics of the in-line aqueous suspension flow; based on the flow profile characteristics, identifying an interface between a water-immiscible flow component and a water-rich flow component of the in-line aqueous suspension flow; and positioning a flow redirection device in accordance with the interface in order to redirect the water-immiscible flow component away from the remainder of the in-line aqueous suspension flow.

[00026] In some implementations, there is provided a method for recovering a low-density material from an in-line aqueous suspension flow, the low-density material having a lower density that water, the method comprising: determining flow profile characteristics of the in-line aqueous suspension flow; based on the flow profile characteristics, identifying an interface between a low-density flow component and an overlying water-rich flow component of the in-line tailings flow; and positioning a flow redirection device in accordance with the interface in order to redirect the low-density flow component away from the water-rich flow component.

[00027] In some implementations, there is provided a method for separating a multi-phase stream, comprising: providing the multi-phase stream comprising a first phase and a second phase that are dispersed together; piping the multi-phase stream to provide a pressure drop sufficient to cause separation of the stream into a first-phase flow component and a second-phase flow component; determining a velocity profile of the multi-phase stream to identify an interface between the first-phase flow component and the second phase flow component; and positioning a flow redirection device in accordance with the interface to redirect the first-phase flow component away from the second-phase flow component.

[00028] In some implementations, the multi-phase stream comprises a liquid-liquid emulsion. In some implementations, the multi-phase stream comprises a liquid-solid slurry, such as tailings, which can be oil sands tailings. In some implementations, the multi-phase stream comprises a liquid-solid-gas slurry. In some implementations, the multi-phase stream comprises a solid-gas mixture.
BRIEF DESCRIPTION OF THE DRAWINGS

[00029] Fig 1 is a side cut view schematic of a system for recovering a flow component.

[00030] Fig 2 is another side cut view schematic of a system for recovering a flow component.

[00031] Fig 3 is a perspective partially transparent view schematic of a system for recovering a flow component.

[00032] Fig 4 is a front cross-sectional view schematic of a pipe and a flow redirection device.

[00033] Fig 5 is a partial perspective view flow diagram.

[00034] Fig 6 is a graph of composition versus location of a flow redirection device.

DETAILED DESCRIPTION

[00035] In some implementations, determining flow profile characteristics of an in-line tailings flow can facilitate identification of a bitumen-rich flow component and positioning of a flow redirection device according to the location of the bitumen-rich flow component.
Enhanced positioning of a flow redirection device can, in turn, improve bitumen recovery from the tailings.

[00036] Referring to Fig 1, in some implementations the bitumen recovery system 10 includes a main pipe 12 supplying the in-line tailings flow 14, a branch pipe 16 in fluid communication with the main pipe 12, a flow redirection device 18 extending into the main pipe 12, and a flow profiler 20 provided upstream of the branch pipe 16 and flow redirection device 18. The flow profiler 20 is configured to determine flow profile characteristics of the in-line tailings flow 14.

[00037] Referring to Fig 2, the flow profiler 20 can be configured to determine a velocity profile 22 of the in-line tailings flow. The velocity profile 22 can include a bitumen flow profile region 24 of a bitumen-rich flow component of the in-line tailings flow. The bitumen-rich flow component overlies a water-rich flow component of the tailings. The bitumen-rich flow component can be a froth-like material including air bubbles, bitumen, and some water and solids. The bitumen froth-like material can tend to have a lower velocity compared to the underlying water-rich component of the tailings flow.

Understanding the depth and position of the bitumen flow profile region 24 allows determining (or estimating) a location of the interface 26 between the bitumen-rich flow component and the underlying water-rich flow component. The flow redirection device 18 can be located based on the estimated location of the interface 26, in order to redirect the bitumen-rich flow component away from the bitumen-poor water-rich tailings flow component and into the branch pipe 14. For instance, there is a flow interface 26 in between the bitumen flow profile region 24 and an underlying water-rich flow profile region 28, and the flow redirection device 18 can be located at or near the flow interface 26. The flow redirection device 18 can be configured to define an inlet region having a distance D1, which can be defined between a lower part of the flow redirection device 18 and the upper wall of the main pipe 12. Dr can be determined based on the distance D, of the flow interface 26 from the upper wall of the main pipe 12. Dr can be generally equal to D, or be provided offset a certain distance from Di.

[00038] The flow velocity profiler can include various different types of velocity profiling devices and can employ various profiling technologies. For example, the flow velocity profiler can be an ADFM device available from Isco, Inc., using pulse-Doppler velocity profiling technology to measure the velocity distribution within the flow. The flow velocity profiler can be a SONARtrace device available from CiDRATM, using sonar flow technology. The flow velocity profiler can be other types of devices that employ acoustic sensor technology for measuring the velocity profile of the in-line tailings flow.

[00039] In some implementations, the flow profiler and the flow redirection device are configured and operated to avoid disrupting the flow profile of the in-line tailings. In addition, the construction and the operation of the overall system can be done to minimize or avoid turbulence or flow eddies that would disrupt the tailings flow both at the flow profiler and at the flow redirection device.

[00040] As illustrated in Fig 2, the velocity flow profile can include an irregularity or change, indicative of the boundaries of the bitumen-rich flow component. For example, in some implementations the velocity flow profile can include a sudden change in velocity gradient indicating the interface of the bitumen-rich flow component with the underlying fluid. In some implementations, the velocity flow profile can include an offset-velocity region or a lower-velocity region in the upper part of the velocity profile, indicating the position of the bitumen-rich flow component. Since the bitumen-rich flow component can be a froth-like material composed of bitumen, air bubbles and some water and solids that have accumulated together, the bitumen-rich flow component can tend to have a lower velocity compared to the underlying water-rich flow component. In some implementations, the bitumen-rich flow component can display other flow characteristics that are different from those of the underlying water-rich flow component.
For example, due to differing fluid properties, such as density and viscosity, the bitumen-rich flow component can display laminar flow regime while the underlying water-rich flow component displays turbulent or more irregular flow regime characteristics.
The upper bitumen-rich regime may also travel at a slower velocity than the lower bitumen poor regime.

[00041] The flow redirection device 18 can have various structures and configurations.
In some implementations, the flow redirection device 18 defines a channel having an upstream inlet, where the inlet is sized according to Dr and the channel is in fluid communication with the inlet of the branch pipe 16. In some implementations, the flow redirection device 18 includes a skimming member configured to skim an upper part of the in-line tailings flow. In some implementations, the flow redirection device 18 is fixed with respect to the main pipe 12. For example, the flow redirection device 18 can be welded in place in order to define a constant distance Dr with respect to the upper wall of the main pipe 12. Alternatively, the flow redirection device 18 can be connected so as to be adjustable and thereby vary the distance Dr in response to the location of the interface 26. In some implementations, the flow redirection device 18 has parts that can be lowered or raised in order to be generally aligned with the interface distance D, to redirect a stream that is rich in bitumen and poor in water and solids.

[00042] Referring to Figs 1, 2 and 3 in some implementations the flow redirection device 18 can have a fixed plate construction. The flow redirection device 18 can include a first plate 30 extending downwardly from the upper wall of the main pipe 12, and a second plate 32 extending from the lower end of the first plate 30 in an upstream direction. The first plate 32 can be configured to extend from the upper wall of the main pipe 12, just downstream of the inlet of the branch pipe 16, in an oblique manner in the upstream direction. The first plate 32 can extend across the entire width of the upper part of the main pipe 12.

[00043] Referring to Figs 3 and 4, the second plate 32 can have a width corresponding to the width of the main pipe at the location within the main pipe 12. The second plate 32 can have side edges 34 that are fixed to the opposed interior walls of the main pipe 12.
The flow redirection device 18 can be constructed such that all of the material flowing above the second plate 32 passes into the branch pipe 16.

[00044] Referring to Fig 5, the bitumen recovery system 10 can be used in combination with a bitumen extraction operation 36 that received oil sands ore 38 and generates bitumen product 40 and extraction tailings 42. The extraction tailings 42 are supplied by a tailings pump 44 toward a tailings containment area 46, which can be a tailings pond for example. The extraction tailings 42 initially have a relatively high hydraulic pressure and the residual bitumen in the tailings can be in the form of droplets dispersed within the tailings. The extraction tailings 42 can be considered a single-phase slurry under such initial high hydraulic pressures. Since the tailings containment area 46 can be relatively remote from the bitumen extraction operation 36, the extraction tailings 42 are =

transported long distances by pipeline 48. The in-line tailings flow decreases in pressure at more remote parts of the pipeline 48, facilitating air bubbles and the dispersed bitumen to coalesce and accumulate as a froth-like bitumen-rich flow component overlying the rest of the tailings flow. This froth-like material can tend to have a lower velocity compared to the underlying water-rich component. This bitumen-rich flow component can be skimmed off of the rest of the tailings, supplied to a holding tank or an interim treatment unit 50, and eventually transported back to the bitumen extraction operation 36 by pipeline or truck. The recovered stream can be subjected to settling in order to produce a bitumen-concentrated froth. The bitumen-concentrated froth can be fed into the primary froth tank and then subjected to secondary froth treatment using diluent addition techniques.

[00045] Referring still to Fig 5, a measurement device 52 can be provided for measuring one or more properties of the high-pressure extraction tailings 42 proximate to the extraction operation 36. A second measurement device 54 can also be provided at a remote downstream location along the pipeline 48 for measuring one or more properties of the in-line tailings flow just upstream of the bitumen recovery system 10.
For example, the second measurement device 54 can measure the pressure of the in-line tailings flow, which can be used to determine the pressure drop that occurred between the two measurement devices 52 and 54. Pressure information can be used to infer certain flow properties of the in-line tailings flow, such as whether the pressure is low enough for the bitumen to accumulate and form the bitumen-rich flow component. In some implementations, a computing unit 56 can also be provided for performing certain calculations based on the measured flow properties based on the measurement devices 52 and 54, in order to estimate certain flow characteristics of the in-line tailings flow. The computing unit 56 can also be used to determine the position of the flow redirection device.

[00046] In some implementations, one or more velocity profilers can be used in order to determine the velocity profile of the in-line tailings flow. Multiple velocity profiles can be determined at a single location along the length of the pipeline 48 and/or at different locations along the pipeline 48.

[00047] Furthermore, the velocity profiles at multiple locations along the length of the pipeline 48 to determine the velocity profiles at various locations. In some implementations, velocity profiles can be determined along the pipeline in order to determine information regarding the phase separation of the bitumen- and water-rich components. In some implementations, velocity profile can be determined along the pipeline in order to determine where the phase separation has been sufficiently established or is sufficiently stable to provide the flow redirection device.
Thus, velocity profiling can be performed in order to facilitate determining not only the vertical position of the flow redirection device at a given location, but also the location along the length of the pipeline. Furthermore, since the bitumen recovered from the tailing is to be transported back to the extraction operation, it can be advantageous to locate the flow redirection device as close to the extraction operation as possible as long as adequate phase separation has occurred.

[00048] The location of the flow redirection device can influence the composition and the flow rate of the stream recovered via the branch pipe. By positioning the flow redirection device in accordance with the flow profile characteristics of the in-line tailings flow, the composition and the flow rate can be manipulated and controlled.

[00049] Turning to Fig 6, the flow redirection device can be positioned at different distances away from the upper wall of the main pipe resulting in different compositions of the recovered stream. In Fig 6, the x-axis indicates the distance Dr of the second plate (i.e., the lower part of the flow redirection device having a plate construction), while the y-axis indicates the composition of an example redirected stream. It should be noted that the scales of the two y-axes are not necessarily the same. At Dr = 1, the bitumen content is relatively low although the proportion of bitumen in the recovered stream is relatively high. At Dr = 6, the bitumen content is relatively high but the bitumen proportion has decreased compared to the previous locations. At Dr = 4, the bitumen content is quite high and the bitumen proportion is also high. This graph illustrates the benefits of locating the flow redirection device at or near the interface of the bitumen-rich and bitumen-poor flow components, in order to increase bitumen recovery while minimizing the water and solids content in the recovered stream. Depending on the desired composition of the redirected stream, the flow redirection device can be located at various heights within the main pipe.

[00050] In addition, the optimum position of the flow redirection device can vary depending on the final destination for the recovered bitumen froth. For example, for recovered froth intended to be sent to a primary extraction plant, recovering the most bitumen at the expense of quality can be preferred. For recovered froth intended to be sent to a froth treatment plant (also referred to as "secondary extraction"), a leaner cut having lower solids and/or water at the expense of bitumen recovery can be preferred.
Furthermore, the choice of destination for the recovered product may in part depend on how one transports the recovered material and the extent of oxidation in the recovered material.

[00051] In some implementations, empirical tests can be performed by positioning tester flow redirection devices at different locations (e.g., different Dr distances) and then determining the composition of the redirected stream, in order to determine the flow profile characteristics. The position of the flow redirection device can then be determined based on the empirically derived flow profile characteristics. For instance, the flow redirection device can be installed based on the tester device that gave the highest bitumen recovery with the lowest water/solids content. As an example, if the x-axis of Fig 6 were from data obtained from six different tester devices, installation of the flow redirection device could occur at position Dr = 4 to maximize bitumen recovery with a reasonably low water/solids content.

[00052] In terms of compositions of the various streams, in some implementations the in-line tailings flow has a bitumen content of below 0.5 wt%, or below 0.2 wt%, the bitumen-rich flow component has a bitumen content of at least an order of magnitude greater that the in-line tailings flow, for example from 2 wt% to 5 wt%. The bitumen-rich flow component can also have a composition that easily concentrates upon settling to produce a bitumen froth having a suitable bitumen concentration for incorporation into the froth treatment operations, for example about 40 wt% to about 45 wt%.
Depending on the bitumen content, the recovered stream can be supplied to various parts of the oil sands operation having inputs with similar compositions.

[00053] In some implementations, various types of tailings streams can be treated in order to recover valuable materials that have a tendency to form discrete in-line flow components. For example, the tailings streams can include water, solid mineral particles, gas bubbles, and valuable materials including hydrocarbons or other water-immiscible compounds. Water-immiscible compounds that tend to form a discrete in-line flow component overlying or underlying the water-rich flow component of the tailings can be recovered using various techniques described herein. Low-density materials that tend to rise and form a discrete in-line flow component overlying or underlying the water-rich flow component can also be recovered using various techniques described herein. The discrete in-line flow component can be detected using a flow profiler and the flow redirection device can then be positioned accordingly.

[00054] In some implementations, various other in-line multi-phase flows can be separated can be treated in order to recover valuable materials that have a tendency to form discrete in-line flow components. In-line liquid-liquid flows, such as hydrocarbon-water flows, can be separated using techniques described herein where a flow redirection device is positioned in an upper or lower part of the main pipe to redirect one of the immiscible liquids away from the other. In-line liquid-solid flows can also be separated using techniques described herein wherein a flow redirection device is positioned in an upper or lower part of the main pipe to redirect a solids-rich or a solids-poor flow component away from the rest of the stream. In liquid-solid scenarios, when the solids are of various different sizes which tend to separate into different areas of the flow (e.g., coarse heavier solids at the bottom and lighter finer solids at the top), the flow redirection device can be positioned in order to separate a fines-rich flow component from a coarse-rich flow component. In-line gas-solid flows can also be separated using techniques described herein.
=

Claims

13

1. A method for recovering bitumen from an in-line tailings flow, the method comprising:
determining flow profile characteristics of the in-line tailings flow;
based on the flow profile characteristics, identifying an interface between a bitumen-rich flow component of the in-line tailings flow and an underlying water-rich flow component; and positioning a flow redirection device in accordance with the interface in order to redirect the bitumen-rich flow component away from the water-rich flow component.

2. The method of claim 1, wherein the flow profile characteristics comprise a velocity profile.

3. The method of claim 1 or 2, wherein the bitumen-rich flow component that is recovered has a bitumen content of at least one order of magnitude greater than a bitumen content of the in-line tailings flow.

4. The method of any one of claims 1 to 3, wherein the flow redirection device comprises a skimmer blade having a lower plate, and the lower plate is located at or near the interface between the bitumen-rich flow component and the water-rich flow component.

5. The method of any one of claims 1 to 3, wherein the flow redirection device is located above the interface to promote a higher bitumen concentration in the bitumen-rich flow component.

6. The method of any one of claims 1 to 3, wherein the flow redirection device is located below the interface to promote a higher bitumen recovery from the in-line tailings flow.

7. The method of any one of claims 1 to 6, wherein the flow redirection device is provided at a fixed position based on the interface.

8. The method of any one of claims 1 to 7, wherein the flow redirection device is configured so as to be adjustable between different positions.

9. The method of any one of claims 1 to 8, further comprising:
supplying the bitumen-rich flow component to a froth treatment operation or a primary extraction operation, to recover bitumen therefrom.

10. A system for recovering bitumen from an in-line tailings flow, the system comprising:
a main pipe for supplying the in-line tailings flow;
a branch pipe in fluid communication with main pipe;
a flow profiler for determining flow profile characteristics of the in-line tailings flow and, based on the flow profile charactersitics, identifying an interface between a bitumen-rich flow component of the in-line tailings flow and an underlying bitumen-poor tailings flow component; and a flow redirection device extending into the main pipe and located in accordance with the interface in order to redirect the bitumen-rich flow component into the branch pipe.

11. The system of claim 10, wherein the flow profiler is configured to determine a velocity profile of the in-line tailings flow.

12. The system of claim 10 or 11, wherein the flow redirection device comprises a skimmer blade.

13. The system of any one of claims 10 to 12, wherein the skimmer blade comprises:
a first plate fixed to the main pipe and extending downwardly into the in-line tailings flow, and a second plate extending from a lower end of the first plate in an upstream direction, the first and second plates defining with an opposed wall of the main pipe a conduit for transferring the bitumen-rich flow component from the main pipe to the branch pipe.

14. The system of claim 13, wherein the second plate is substantially parallel with the opposed wall of the main pipe.

15. The system of claim 13 or 14, wherein the second plate is at or near the interface between the bitumen-rich flow component and the bitumen-poor tailings flow component.

16. A method for extracting bitumen from an oil sands ore, comprising:
separating an oil sands ore into a bitumen product stream and a tailings stream comprising water, solid particles and dispersed residual bitumen;
supplying the tailings stream toward a tailings containment area via pipeline to induce a pressure drop and form an in-line tailings flow having a reduced hydraulic pressure;
determining flow profile characteristics of the in-line tailings flow;
based on the flow profile characteristics, identifying an interface between a bitumen-rich flow component of the in-line tailings flow and an underlying water-rich flow component; and positioning a flow redirection device in accordance with the interface in order to redirect the bitumen-rich flow component away from the water-rich flow component.

17. A method recovering bitumen from tailings, comprising:
producing a tailings stream from a bitumen extraction operation, the tailings stream comprising a dispersed mixture of bitumen, water and solids;
piping the tailings stream to induce a pressure drop sufficient to cause separation of the tailings stream into a bitumen-rich flow component and a water-rich flow component;
determining a velocity profile of the tailings stream to identify a location of the bitumen-rich flow component within the tailings stream;

based on the location of the bitumen-rich flow component, positioning a flow redirection device in the tailings stream to redirect the bitumen-rich flow component away from the water-rich flow component.

18. Use of a flow velocity profiler for identifying a location within an oil sands tailings pipeline to position an in-line bitumen skimmer.

19. The use of claim 18, wherein the location is an interface between a bitumen-rich flow component and a water-rich flow component.

20. The use of claim 19, wherein the in-line bitumen skimmer comprises a fixed skimmer blade positioned at the interface.