Optimizing server inlet areas for enhanced thermal management in data centers: A CFD-based investigation

• Published in: International communications in heat and mass transfer Vol. 168; p. 109432
• Main Authors: Cao, Shuanghua, Wu, Tong, Ling, Jingyue, Wu, Lijing
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 01.11.2025
• Subjects: Airflow distribution; Computational fluid dynamics; Data center thermal management; Energy efficiency; Server inlet optimization; Temperature uniformity; Airflow distribution; Temperature uniformity; Server inlet optimization; Energy efficiency; Computational fluid dynamics; Data center thermal management
• ISSN: 0735-1933
• DOI: 10.1016/j.icheatmasstransfer.2025.109432

Energy consumption in data center cooling systems remains a critical challenge, accounting for approximately 50 % of total operational costs. This study presents a novel approach to optimize thermal management in data centers through server inlet area adjustments, validated using a data center facility. Computational fluid dynamics (CFD) simulations incorporating detailed server temperature equations show significant thermal differences in the vertical direction, particularly, the bottom row of servers is subject to significant overheating (309.2 K). The optimization strategy in this study aims to maintain constant air supply parameters (291 K, 2 m/s) while formulating an inlet sizing optimization equation based on the vertical static pressure distribution analysis. This approach ensures a uniform airflow distribution, effectively lowering the temperature at the bottom of the servers to 299.9 K. Additionally, the thermal uniformity in the vertical direction of the cold aisle was significantly enhanced, the temperature gradient between rows was reduced to less than 1 K, thereby adhering to the ASHRAE standard. This cost-effective solution demonstrates practical value for thermal management in high-density data centers, optimizes airflow distribution within the cold aisle and provides potential energy savings without additional cooling infrastructure investment. •Novel server inlet area optimization method achieves uniform thermal distribution•Bottom-row server temperatures reduced from 309.2 K to 299.9 K without additional energy input•Inter-row temperature differential decreased to less than 1 K through inlet area adjustment•Cost-effective solution requires no modification to existing cooling infrastructure•Validated approach using CFD simulation and experimental data