Abstract:This study investigates the flow characteristics and shear granulation mechanisms of high-viscoelastic gels during the granulation process, which holds significant importance for the industrial production and application of dispersed particle gels. The granulation process of high-viscoelastic gels within shear devices is simulated to analyze changes in the pressure field, velocity field, and shear rate field, thereby revealing the flow patterns during granulation. The shear granulation mechanisms under various parameters such as liquid mixing ratios, shear rotation speeds, shear distances, staggered tooth distances, and tooth arrangement angles are also studied. The results indicate that the shear device can be primarily divided into two regions: a high shear rate fragmentation region and a particle mixing region with minimal pressure values. Through single-factor influence analysis and orthogonal experimental simulations, the contributions of shear parameters to pressure, velocity, and shear rate in the flow field were clarified. Four types of bulk gels—low temperature and low salinity, moderate temperature and moderate salinity, high temperature and high salinity, and ultra-high temperature and ultra-high salinity—are examined for their viscosity, particle size, and microstructure changes during the shear granulation process in granulation equipment. This process includes three stages: shear fragmentation, mixed grinding, and particle uniformity. Taking high temperature and high salinity bulk gels as an example, adjustments to the liquid mixing ratio (1:0~1:9), shear rotation speed (1160rpm~2900rpm), shear distance (1mm~5mm), staggered tooth distance (1.5mm~3mm), and tooth arrangement angle (-6°~6°) allow for real-time adjustment of the dispersed particle gel size. By employing simulation and laboratory experiments, the impact of different shear parameters on the dispersed particle gel system was studied, identifying influencing factors for the granulation of high-viscoelastic gels. This provides references for practical applications.