Energy Efficiency, Local Entropy Sources and Exergy Analysis in Measuring Orifice Plates: A Computational Fluid Dynamics Approach

Accurate flow measurement is crucial for energy efficiency in industrial applications. This study investigates entropy generation in measuring orifice plates under high-pressure conditions (80 bar, 400 °C) using computational fluid dynamics (CFD) in OpenFOAM. Two turbulence models, k-ω SST and Spalart–Allmaras, are employed to analyze compressible steam flow and identify local entropy sources. Building on recent findings, this research explores the hypothesis that the discharge coefficient reflects entropy generation. The orifice plate’s abrupt flow contraction and expansion contribute to significant energy dissipation, affecting exergy efficiency. By quantifying entropy sources through numerical simulations, this study provides insights into optimizing flow metering techniques and reducing irreversibilities. The results show a strong correlation between entropy generation and the discharge coefficient, offering a new approach to improving measurement accuracy. This research supports the advancement of energy-efficient flow measurement methods, aligning with sustainable engineering practices.