Blog

High-Density Data Center Thermal Validation using CFD
Engineering Simulation

High-Density Data Center Thermal Validation using CFD

How to guarantee the cooling of the critical IT load before installing the first server?

In critical infrastructure design, uncertainty is the greatest enemy of profitability. To ensure success, Data Center thermal validation is a fundamental step. When facing High-Density projects, exceeding 8-9 kW per rack, traditional rules fail. Spreadsheets are no longer sufficient. Phenomena such as hot air recirculation or cold air bypass are dangerous. Static pressure loss in the raised floor can also compromise operations from Day 1.

In this article, we demonstrate how our team at Atreydes Engineering utilizes Computational Fluid Dynamics (CFD). We use high-precision algorithms to perform Data Center thermal validation and optimize complex designs. This ensures compliance with thermal SLAs under any load scenario.

Modelo geométrico de la validación térmica de Data Centers. Análisis realizado por Atreydes Ingeniería.
Geometría Data Center

The Challenge: 24 High-Density Racks and 230 kW of Heat

We recently undertook the analysis of an IT room designed to house 24 racks. Each rack has a load of 9.6 kW. The room is cooled by a raised floor downflow system with two perimeter CRAC units.

The challenge was not just “cooling the room,” but answering critical questions:

Is the system capable of maintaining the necessary 12°C ΔT?
Are the floor tiles/grilles correctly sized to avoid airflow bottlenecks?
What is happening regarding airflow dynamics under the raised floor with the massive flow rates of modern machines?

Our Methodology: Beyond Basic Simulation

Many studies fail because they oversimplify the physics. Our approach to Data Center thermal validation is based on rigorous modeling. We replicate real fluid behavior.

1. "Lumped" Modeling with Physical Precision
Instead of simple visual geometries, we model racks as porous media. We use anisotropic inertial resistance. We mathematically define the internal barriers of the servers. This forces air to follow realistic Front-to-Back patterns. We detect internal recirculations that simple models ignore.
2. Advanced Characterization of the Raised Floor
For 9.6 kW loads, a standard tile is effectively a plug. We implemented models of High-Flow Tiles with 60% free area. We calibrated the resistance coefficients to simulate the exact pressure drop (12-15 Pa). This allows us to predict plenum behavior. We know if static pressure will be sufficient to "feed" the furthest servers.
3. Managing Complex Physics (Troubleshooting)
One of the greatest values of CFD specialists is the ability to interpret anomalies. During this study, we detected and corrected critical risks like the Venturi Effect. We identified zones of negative pressure near the CRACs due to high exit velocity.

Containment Strategies: Cold, Hot, or Open Aisle?

We validated a Cold Aisle Containment (CAC) architecture in this case. However, our consulting services evaluate the suitability of the topology based on load density:

Cold Aisle Containment (CAC):
Ideal for medium-high densities. We analyze pressure balancing to prevent the containment from inflating or collapsing. We adjust the CRAC ventilation curve.
Hot Aisle Containment (HAC):
Recommended for extreme densities (>15 kW) or Slab Floors. Here, the simulation challenge changes. We analyze thermal stratification of the entire room to ensure efficient return.
Legacy / Open Aisle:
For audits of existing centers. We quantify losses due to air mixing. We justify the ROI of retrofitting containment with data.

Study Results

Thanks to this preventive Data Center thermal validation, we delivered actionable conclusions to the client:

Flow Rate Validation
We verified that the airflow of 34,000 m³/h was sufficient. We maintained supply at 22°C and return at 34°C, complying with ASHRAE standards.
Elimination of Hot Spots
Micro-hot spots were detected in the upper area of central racks. We corrected this by adjusting tile permeability in the model. This optimized distribution at no additional hardware cost.
Hydraulic Stability
The 60cm plenum was confirmed to be sufficient. It handled backpressure without generating turbulence that would affect the CRAC sensors.

Why Outsource Your CFD Studies With Us?

Software is just the tool; the value lies in the interpretation of the physics.

Conducting these studies in-house is complex. It requires expensive licenses and high-performance computing hardware. It also demands a steep learning curve to avoid convergence errors.

Our proposal is simple: We handle the mathematical and computational complexity. You receive a validated report guaranteeing the design’s performance.

Do you have a critical project or a design that needs thermal validation? Let’s talk about how we can apply these advanced methodologies to your next Data Center.

Sección transversal de líneas térmicas de flujo en la validación térmica de Data Centers. Análisis realizado por Atreydes Ingeniería.
Cold Aisle Containment (CAC)

About Us

Industrial,Designer,Has,Conversation,With,Senior,Engineer,While,Working,In
More than 10 years of experience in engineering, applying synergy of several technical areas together with new technologies to guarantee the success of our customers.