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Liquid Cooling and Heat Rejection · Part 3 of 7

Act 3 — The Numbers You Actually Have To Get Right

Building the model…

A direct liquid loop: cold plates, rack manifolds, the CDU's heat exchanger and the facility loop to outside. Drive the heat and the ΔT and watch the flow.

Three quantities determine whether a loop works: how much heat, how much flow, and at what temperature. They are joined by one equation, and it is worth carrying in your head because it settles most design arguments in a single line.

For water, specific heat capacity is about 4.18 kJ/kg·K, and one litre per minute is one kilogram per minute. So:

Heat removed (kW) = flow (L/min) × ΔT (K) × 0.0697

Which rearranges to the form you use on site: one litre per minute removes about 0.07 kW for every kelvin of temperature rise.

Work an NVL72 rack through it. At 142 kW and a 12 K rise across the rack, required flow is 142 ÷ (0.0697 × 12) ≈ 170 L/min, roughly 45 US gallons per minute, into a single cabinet. Widen the design ΔT to 15 K and the same heat needs 136 L/min; narrow it to 8 K and it needs 255 L/min. That trade is the whole of secondary-loop design: higher ΔT buys smaller pipes, smaller pumps and less parasitic power, and it costs you approach temperature at the cold plate.

Supply temperature is a facility decision with a silicon constraint. ASHRAE's liquid classes are named for their maximum supply temperature — W17, W27, W32, W40, W45 — and the higher classes are the interesting ones, because a loop that runs at 32–45 °C supply can reject heat to ambient air through dry coolers for most of the year in most climates, and never start a compressor. That is where the operating-cost argument for liquid actually lives; it is not the pumps, it is the chillerless hours. The constraint is that every degree of supply temperature is a degree you have spent before the coolant reaches the die, so the vendor's maximum inlet specification for the tray is the number that caps your ambition, not the chiller's capability.

Pressure and approach. Cold plates and quick disconnects each contribute pressure drop; a rack's full hydraulic path — manifold, hoses, UQDs, microchannels — typically lands somewhere between 1 and 2 bar at design flow. Secondary pumps are sized for that plus the header run, and the CDU regulates to a differential pressure across the manifold rather than to a flow number, because flow redistributes as trays are added and removed. If you take a tray out and cap the port, the remaining trays get more flow, not less; if you take a tray out and leave the port open, you have a leak.

QuantityTypical design pointWhy it moves
Secondary supply temperature30 – 45 °CHigher enables chillerless operation; capped by tray inlet spec
Rack ΔT10 – 17 KHigher shrinks pumps and pipes; lower improves die margin
Flow per rack~1.0 – 1.5 L/min per kWFalls out of the ΔT you chose
Manifold differential pressure1 – 2 barSum of cold-plate, hose and UQD losses
Filtration50 µm typical, finer at the CDUMicrochannels are the smallest aperture in the system
Residual air load10 – 25 % of rack powerDIMMs, drives, optics, VRs not on plates
QuantitySecondary supply temperature
Typical design point30 – 45 °C
Why it movesHigher enables chillerless operation; capped by tray inlet spec
QuantityRack ΔT
Typical design point10 – 17 K
Why it movesHigher shrinks pumps and pipes; lower improves die margin
QuantityFlow per rack
Typical design point~1.0 – 1.5 L/min per kW
Why it movesFalls out of the ΔT you chose
QuantityManifold differential pressure
Typical design point1 – 2 bar
Why it movesSum of cold-plate, hose and UQD losses
QuantityFiltration
Typical design point50 µm typical, finer at the CDU
Why it movesMicrochannels are the smallest aperture in the system
QuantityResidual air load
Typical design point10 – 25 % of rack power
Why it movesDIMMs, drives, optics, VRs not on plates
LOOP SIZING
Flow, ΔT and the residual air budget
Rack load (kW)142 kW
Design ΔT (K)12 K
Residual air share15 %
Rack load
total electrical draw of the cabinet
142 kW
To liquid
85% on cold plates
120.7 kW
To air
DIMMs, drives, optics, regulators
21.3 kW
Secondary flow
38 US gpm into one rack
144 L/min
Flow intensity
falls out of the chosen ΔT
1.20 L/min per kW
Widening ΔT shrinks pipes and pumps and costs die margin. Narrowing it does the reverse. Water: 4.18 kJ/kg·K, so 1 L/min removes 0.0697 kW per kelvin.

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