International Journal of Emerging Technology and Advanced Engineering Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 5, May 2013) 588 Design and Development of Low Cost I.C. Engine Based Waste Heat Recovery System Mukesh Rathore 1 , Manoj Kumar Sain 2 , Dr. V. K. Gorana 3 1,2 Mechanical Engineering Department, Swami keshvanand Institute of technology and Gramothan Jaipur Rajasthan 3 Mechanical Engineering Department, Rajasthan Technical University, Kota, Rajasthan Abstract— This study proposed a the new cost effective design of diesel exhaust waste heat recovery system (WHRS) for Bus rapid transport System (BRTS, Jaipur) and Stationary System and proposes a cost effective robust design that meets the principle design constraints for WHRS. In order to address various design constraints for WHRS while achieving the required performance of the system, numerical analysis and optimization was carriedout using CFD software Ansys FLUENT and Ansys WB (Parametric Study).Possible waste heat recovery system geometries studied that meets both Indian Pollution control standard and geometries constraints. Based on the numerical analysis, author proposed a new kind of WHRS that meets the performance specifications but is outside of the space constraints of BRTS. The WHRS perform at approximately 0.3 to 0.6 efficiency; providing 10 kW at ideal conditions. The overall length of the system is 1200 mm and the overall width is 550 mm. The weight of the heat exchanger is 100 kg; therefore, it does not meet the weight constraint. The overall cost of the WHRS is INR 15000 which is within budget for BRTS, Jaipur. Keywords— CFD, Low cost system, Optimization, WHRS. I. INTRODUCTION The heat recovery from exhaust gases of I. C. engine has become vital due to the declining conventional energy resources and increasing cost of these sources year wise and that why need to use energy more efficiently has become a necessity since the large increase in fuel prices [1]. The number of vehicles (passenger and commercial vehicles) produced from 2001 to 2011 in Jaipur, Rajasthan shows an overall increasing trend from year to year in the2008–2010periods. (Fig. 1(a) and (b)). As shown in fig 1 high growth rate of vehicles, pressurized the researchers and engineers to reduce the amount of waste heat discharged from I. C. Engine to the environment [2]. Fig. 1 (a) Passenger Vehicles (RTO, Jaipur) Fig. 1 (b) Commercial Vehicles (RTO, Jaipur) The waste exhaust gases from various sources at different temperature ranges are usually discarded into the local environment which could otherwise be used for some useful purposes for the society. Heat recovery conserves energy, reduces the overall operating costs and finally reduces peak loads from automotive body. Best method to recover the heat from exhaust is the heat exchanger.