This works demonstrates the waste heated gases from the engine were utilised to heat other fluid using heat exchangers. Various designs of the heat exchangers were modelled using computer aided design and analysis was done using a computational fluid dynamics code which is commercially available to study the flow and heat transfer characteristics. Ideal heat exchangers recover as much heat as possible from an engine exhaust at the cost of an acceptable pressure drop. Present research work is complete for heat recovery from exhaust gas of I C engine using rectangular and circular type pipe heat exchanger. Design of experiment technique is used for present research work and analysis of variance is also performed for model equation generation. Experimental validation is performed for base fluid air based results are solved using CFD simulation method. Ansys fluent software is discussed in present study and the optimisation is done to have the maximum heat recovery amount and minimum of pressure drop along the heat exchanger.

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