Heat Recovery and Rejection Systems

Ultimately, the heat generated from industrial process and chillers must be rejected to some heat sink, or the heat recovered and re-used. Evaporative cooling towers, dry-coolers, geo-thermal loops, rivers and lakes are utilized in open and closed loops. When possible, the recovery of waste heat and returning it to useful purposes is our objective. For high quality process waste heat, absorption chillers may be beneficial. In other conditions, energy can be better utilized by placing heat exchangers between the process heated fluids and the outdoor cooler air in order to recover the heat energy.

A recent project to cool induction furnaces includes four air cooled chillers and a plate and frame heat transfer station dedicated to each chiller. The system includes a bank of two dry-coolers piped in series and with an automatic valve to divert chilled water return flow through the free coolers whenever the ambient is 60°F or below. This trims the delta-t and reduces the chiller load. The system is designed to provide 100% free-cooling as ambient drops.

This is a critical-duty application for a large multi-national manufacturer. Consistent and reliable operation are paramount. FCS was selected because of our well known experience in the trenches of process cooling applications, ruggedized PLC controls, attention to detail and quality-controlled manufacturing from inception through final commissioning.
Cooling towers are available in a variety of materials and flow patterns, Shown are dual Rymsa cooling towers known for effective cooling and cost effective products. Towers with stainless-steel constructions, basin cleaners and VSD fans are available.


Cooling towers and evaporative condensers from CTI rated manufacturers are acceptable. Open or closed systems, operating over what range and climate may dictate the best type of tower or brand.

Fiberglass cooling towers are cost-effective, have a 30-year life expectancy, are CTI certified and are backed by a 15-year fiberglass warranty. This is a reasonable alternative to our metal cooling tower options..

• Environmentally friendly: supports water treatment. No passivation.

• Motors: marine duty, premium efficiency, cast iron.

• Corrosion-resistant materials.

• Wide access doors.

• PVC fill with UV protection, fire resistant, non-combustible.

• We fabricate our own support structures

• Stainless-Steel is available


An air cooled heat exchanger system uses the ambient air temperature to cool a fluid circulating through a coil. This type of cooling can be used when the fluid being cooled is as close as 5°F or higher than ambient temperature.

An air cooled heat exchanger, often referred to as a dry-cooler is comprised of a coil, inlet/outlet headers, fans, motors, structural stand and several potential options.

Adiabatic systems can further reduce energy for heat rejection to dry coolers. Data-center adiabatic systems utilize fine filtration and reverse osmosis water treatment. Controls correlate relative humidity and heat load to enable minimal make-up water usage.

remote dry coolers, condensers, process cooling systems, heat transfer, heat recovery, process cooling HVAC systems, chillers
Dry-coolers can be V-Shape and include adiabatic such as this model by Guenther


Recover waste heat whenever possible. Depending on the waste heat available, and the need for chilled water, absorption chillers may be our best option.

plate heat exchangers, heat recovery systems, free cooling, modular heat transfer systems, heat exchanger stations
Plate heat exchangers deliver excellent approach temp and cleanability.

For many climates, free-cooling during colder months is practical is easily integrated into FCS Modular Chiller Plants.

For certain applications using oil-free centrifugal chillers, thermosiphon free-cooling and even refrigerant economizers using evaporative condensers are available to reduce the kW demand for producing chilled water.

Free-cooling often includes a close-approach plate heat exchanger that is connected to the chilled water supply loop. When ambient conditions allow, the cooling tower and free-cooling system provides enough cooling to stage off the chillers. With proper sensors, valves, and controls, this is an automatic switchover.

Process cooling system, outdoor coolers, dry coolers, cooling towers, heat exchangers, heat transfer system, tanks, pump systems.
Heat rejection using dry-coolers is appropriate when the required process temperature is achievable using outdoor ambient air temperature without requiring evaporation. This approach conserves the use of water. Adiabatic assist systems using small amounts of spray water at the dry cooler coils can further reduce temperatures and energy usage.

Cooling Tower Features

All FRP unitized casing and internal structure. Stainless-steel is also available.

Stainless steel hardware

Complete structures with safety-ladders, rails and walkways for elevated cooling towers are available.

UV Protection for extended life & strength

Optimum Design for all season performance including freezing climates

Fiberglass-Reinforced-Polyamide adjustable pitch Fans

Self extinguish PVC fill & PVC drift eliminator

Direct drive, low speed, TEFC, Inverter Duty, Marine Duty, NEMA fan motors

Low noise operation

No moving internal parts

Fixed non-clog distribution nozzles with variable flow rates

Triple-pass PVC Air Inlet Louvers

Large, easily removable access doors

Corrosion resistant strainers

Single or multiple fan configurations with common sump

Greater resistance against chlorides, sulfates, total dissolved solids and pH instability

No passivization process needed, no fear of “white rust”

Complete cooling tower structures are available for one or multiple cooling tower systems. OSHA approved safety ladders, rails and walkways. Cooling tower and structure includes a davit
Three-Cell Cooling Tower with three heat transfer skids, two operate and one dedicated system in standby. System includes duplex pump skid and emergency cooling pump skid with immersion heaters. System cools a critical duty hot-metal stamping factory.

Air-Cooled Heat Exchangers and Dry-Coolers

Our coil tubes and fins can be manufactured using copper, stainless steel, aluminum, steel and galvanized steel

Inlet/Outlet Headers
Headers can be threaded pipe, flanged pipe, boxed end headers and plugged headers

Aluminum and Plastic fan blades are used in several different configurations.

Fan Arrangement
Induced Draft or Forced Draft

NEMA and EC. Direct drive or Belt driven

Structural Stand
Heavy duty galvanized steel with a polyurethane paint, galvanized steel (no paint) or aluminum

Dry-coolers and condensers with and without adiabatic assist are available.


  • Epoxy coated fins
  • E-Coat over entire coil
  • Air filters
  • Fin spacing to meet specific applications
  • Individual fan disconnects
  • Custom mounting legs to meet height requirements
  • Vibration dampers
  • Control panels
  • Pump Station
  • Adiabatic Design (lowers dry bulb temperature of air before going over the cooling coil)

2441 E. Bristol Rd, Burton, MI  48529
Phone: 888-315-5631
Fax: 888-423-1914

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