Entropy Generation-Based Assessment of Thermodynamic Irreversibility in Turbulent Conjugate Heat Transfer Systems Under Realistic Boundary Conditions

Entropy generation analysis provides a thermodynamic framework for quantifying irreversibility in thermal systems. However, most existing second-law studies rely on simplified boundary conditions and do not consider fully coupled conjugate heat transfer involving fluid convection, wall conduction, and external heat exchange. Consequently, thermodynamic assessments under realistic conditions remain limited. This study presents an entropy generation-based assessment of turbulent conjugate heat transfer in circular pipes by considering the combined effects of wall thickness ratio (0.02–0.08), wall thermal conductivity (0.2–400 W/m·K), and external convection (5–100 W/m2·K). A three-dimensional steady RANS-based conjugate heat transfer model is employed, and entropy generation is evaluated to quantify irreversibility within fluid and solid domains. The results indicate that wall-related thermal resistances significantly affect thermodynamic performance. Variations in wall conductivity lead to approximately 15–20% changes in total irreversibility, while increasing external convection from 5 to 20 W/m2·K results in up to 25–30% variation. Increasing wall thickness enhances conductive entropy generation, whereas higher Reynolds numbers increase overall irreversibility. These findings demonstrate that the Biot number is a key parameter governing irreversibility distribution. The results provide energy-efficient design insights for optimizing thermally coupled engineering systems under realistic operating conditions.