This paper addresses the thermodynamic optimum of single-phase convective heat transfer in fully developed flow for uniform and constant heat flux. The optimal Reynolds number is obtained using the entropy generation minimization (EGM) method. Entropy generation due to viscous dissipation and heat transfer dissipation in the flow passage are summed, and then minimized with respect to Reynolds number based on hydraulic diameter. For fixed mass flow rate and fixed total heat transfer rate, and the assumption of uniform heat flux, an optimal Reynolds number for laminar as well as turbulent flow is obtained. In addition, the method quantifies the flow irreversibilities. It was shown that the ratio of heat transfer dissipation to viscous dissipation at minimum entropy generation was 5:1 for laminar flow and 29:9 for turbulent flow. For laminar flow, the study compared non-circular cross-sections to the circular cross-section. The optimal Reynolds number was determined for the following cross-sections: square, equilateral triangle, and rectangle with aspect ratios of two and eight. It was shown that the rectangle with the higher aspect ratio had the smallest optimal Reynolds number, the smallest entropy generation number, and the smallest flow length.
