Direct-to-chip cooling · capex + CDU sizing calculator

DTC cooling capex, opex and TCO calculator — 167→168 CDUs, $42K per rack, $423 per kW IT, $56M 7-year TCO
Companion tool · DTC cooling deep-dive

Direct-to-chip capex, opex + TCO calculator

Author-built engineering scenario model. CDU sizing, per-rack and campus capex, annual opex, and 7-year TCO derived from six architectural inputs. Fig C15 anchors and free-cooling scenario detail below.

6 inputs · 11 outputs · anchored to Fig C15 of the parent essay · free tool · scenario-shareable · Markdown export
500 racks × 100 kW = 50.0 MW IT ÷ 300 kW/CDU = 167 base + N+1 = 168 CDUs $21.1M capex + $5.0M opex/yr

Inputs

Architecture

40 kW = enhanced air. 60–150 kW = DTC single-phase (Blackwell → early Rubin). 180 kW+ = DTC two-phase transition (author threshold, not industry standard). 250 kW+ = two-phase DTC economical; immersion is a distinct architecture at this density, not modelled here. Rubin Ultra 2027 targets ~1 MW / rack.
Number of AI compute racks in the hall.
N+1 modelled as one spare CDU at the hall level. Real deployments may apply N+1 by row, zone or CDU group.
The model treats two-phase as economically relevant above ~180 kW/rack (author model assumption, not an industry standard) and disables the toggle below that density. When selected, two-phase adds 1.35× capex on cold-plate + CDU + controls and reduces pump-power fraction to 0.6× (heat rejects partly through phase change). Immersion is a separate architecture, not modelled here.
32 °C requires facility chiller (higher PUE, +20% facility-loop capex). 45 °C enables dry-cooler free cooling in most climates (lower PUE, −15% facility-loop capex). Currently at 45 °C · facility-loop slice ×0.85 vs the 40 °C neutral baseline.

Operating economy

Cooling + facility overhead energy divided by IT energy. Free-cooling DTC lands 1.08–1.15. Legacy chilled-water halls 1.35–1.50. Auto-suggested from tsup on load; adjust freely.
Levelised wholesale + delivery. US hyperscale bulk 0.06–0.09; EU industrial 0.10–0.14; India/APAC industrial 0.07–0.12; retail 0.15+.
Fraction of design-load IT power actually drawn on average. AI training clusters run 70–90%; inference fleets 40–70%.
TCO = capex + cumulative opex over N years. AI DC capex typically depreciates over 5–10 years.
Advanced · capex and opex overrides
CDU capacity per unit (kW)
In-row 30–500 · row 300–800 · hall 500–1000+
Two-phase capex multiplier (×)
Applied to cold-plate + CDU + controls
Air trim $/rack @ 100 kW
Cold-plate + TIM $/rack @ 100 kW
Manifold $/rack @ 100 kW
QDs $/rack @ 100 kW
CDU share $/rack @ 100 kW
Facility loop + rejection $/rack @ 100 kW
Controls + leak $/rack @ 100 kW
Install $/rack @ 100 kW
Preventive maintenance % capex / yr
Industry range 2–5% of installed capex
Coolant refresh % of coolant capex / yr
Annuity revenue pool (Ecolab, 3M, Chemours)
Pump-power fraction of IT (1-phase, %)
Two-phase reduces to ~0.6× (heat rejects through phase change)
Water $/m³ (evap only, tsup<40)
US industrial 1–3; EU 2–6; scarce basins 6+
Every capex slice interpolates linearly between the essay's 40 / 100 / 250 kW anchor stacks. Above 250 kW the 100→250 slope continues. Every opex assumption is exposed above and can be overridden.
Capex · reference case
$21.1M campus  ·  168 CDUs
$42.3K per rack · $423/kW IT · 50.0 MW IT heat load · N+1 · 45 °C tsup
168
CDUs
99%
CDU util.
$42K
$ / rack
$423
$ / kW IT
50
MW heat load
48%
Tech-side

Capex composition · per rack + campus aggregate

Slice$/rackAggregate% baseline
Cold-plate + TIM$5.0K$2.50M11%
Manifold$3.0K$1.50M7%
QDs$1.0K$0.50M2%
CDU share (base)$8.0K$4.00M18%
Controls + leak$3.0K$1.50M7%
Facility loop + rejection$12.0K$6.00M27%
Air trim$4.0K$2.00M9%
Install + commissioning$8.0K$4.00M18%
Baseline anchor · Fig C15 · @ 100 kW$44.0K$22.00M100%
tsup adjustment · 45 °C, −15% facility slice−$1.8K−$0.90M
CDU redundancy uplift · N+1 spare+$0.05K+$0.02M
Adjusted scenario total$42.3K$21.13M
Baseline row sums the 100 kW anchor stack from Fig C15 with no adjustments. Adjustment rows show every deviation from the anchor so the arithmetic is transparent. Adjusted total = baseline anchor + all applicable adjustments.

Capex waterfall · anchor → adjustments → scenario total

Model boundary · technology-side vs facility-side

Technology-side · 48% Facility-side · 52%
Technology-side share rises with density. Facility loop and rejection are approximately fixed in dollars per rack, so their share compresses as compute-side slices grow.

Annual operating costOpex · year 1 breakdown

Year-1 opex · reference case
$5.0M / year  ·  $100/kW-yr
$14.3/MWh IT · 24% of capex / year · dominated by facility electricity

Opex composition · year 1

Line$/rack/yrCampus/yr% total
Facility electricity (IT × (PUE − 1) × util × 8760 × $/kWh; includes pump + fans + chillers)$8.4K$4.20M84%
of which pump electricity (pump fraction × IT × util × 8760 × $/kWh; two-phase: 0.6×)$0.8K$0.42Msub
of which non-pump overhead (chillers, fans, controls, facility)$7.6K$3.78Msub
Preventive maintenance (% capex / yr)$1.5K$0.74M15%
Coolant chemistry + refresh (% of coolant capex / yr)$0.1K$0.05M1%
Water (evaporative rejection only, tsup<40°C)$0$0.00M0%
Total opex / year$10.0K$4.99M100%
Facility electricity is the single PUE-derived line: total IT × (PUE − 1) × utilisation × 8760 × $/kWh. Pump electricity is shown as an analytical sub-component of that total, not an additional adder, so pumps are not double-counted. When two-phase is selected, pump fraction drops to 0.6× and the effective PUE for opex is reduced by the pump saving; the pump sub-row and the non-pump sub-row still sum to the facility-electricity line above. Chiller electricity at low tsup is captured through PUE.

Full lifecycleTotal cost of ownership

TCO = capex + opex × horizon (default 7 years)
$21.1M
Capex (day 0)
$34.9M
Opex cumulative 7 yr
$56.1M
Total cost of ownership
$1,121
$/kW IT (TCO)
Opex dominates TCO from about year 3-5 onwards at hyperscale energy prices. That reshapes the vendor conversation: efficiency and reliability discounts compound; upfront-only capex framings understate what the operator actually spends.

TCO growth · capex + cumulative opex over horizon

Bottom band = day-0 capex (constant). Stacked bands = annual opex accumulating. Break-even (vertical marker) is the year cumulative opex crosses capex.

Payback engine · architectural switch economics

Free cooling · 45 °C vs 32 °C tsup

Dry cooler + free cooling versus chilled-water facility loop
Capex delta (per rack)−$1.8K
Capex delta (campus)−$0.90M
PUE delta1.35 → 1.15 (−0.20)
Electricity cost delta / year−$5.6M/yr
45 °C wins on both capex and electricity · immediate economic advantage

Two-phase premium · single vs two-phase

1.35× on cold-plate + CDU + controls; pump power drops to 0.6×
Capex delta (per rack)Only at ≥ 180 kW
Capex delta (campus)
Pump-power delta−40% pump fraction
Electricity + opex delta / year
Set density ≥ 180 kW to compute

Sensitivity matrix · year-1 opex under different power price × utilisation

Electricity \ IT util.50%
inference
75%
mixed
90%
training-heavy
$0.06 / kWh bulk US$3.2M$4.2M$4.8M
$0.10 / kWh EU / industrial$4.4M$5.8M$6.7M
$0.14 / kWh peak / constrained$5.6M$7.4M$8.5M
Total year-1 opex (facility electricity + maintenance + coolant refresh + water) at the current scenario's capex, phase, tsup and other settings — varying only power price and IT utilisation. Facility electricity is PUE-derived and already includes pump electricity as an analytical sub-component. The cell nearest the current input pair is highlighted.

Density transition · same rack count, redundancy, coolant temperature and unit costs

40 kW
Enhanced air
Capex$6.6M
$/kW IT$328
Opex/yr$1.9M
7-yr TCO$20M
CDUs0
100 kW
DTC single-phase
Capex$21.1M
$/kW IT$422
Opex/yr$5.0M
7-yr TCO$56M
CDUs168
250 kW
DTC two-phase (immersion is separate)
Capex$41.9M
$/kW IT$335
Opex/yr$12.1M
7-yr TCO$126M
CDUs418
500 kW
Extrapolated · Rubin-class
Capex$76M
$/kW IT$306
Opex/yr$24M
7-yr TCO$244M
CDUs835
All four densities use the current rack count, redundancy, coolant temperature, PUE, electricity price, utilisation and unit-cost overrides. 500 kW extrapolates the 100→250 slope; treat as directional rather than validated. Opex/kW-yr falls slightly as density rises because pump and maintenance costs are relatively fixed per rack while IT power scales linearly.
Illustrative scenario model. Default values are author assumptions. Intended for architecture comparison and investment scenario analysis, not detailed mechanical/electrical design or procurement. Every input is configurable, every formula is exposed in the methodology at the bottom.
Methodology

Capex · anchor points and interpolation

Three anchor stacks from Fig C15 of the parent essay drive the capex model:

40 kW  → $14K/rack (air 8, facility 6)
100 kW → $44K/rack (air 4, cold-plate 5, manifold 3, QD 1, CDU 8, facility 12, controls 3, install 8)
250 kW → $87K/rack (air 7, cold-plate 12, manifold 5, QD 2, CDU 18, facility 22, controls 6, install 15)

Each capex slice interpolates linearly between adjacent anchor stacks: 40→100 uses the 40 and 100 stacks, 100→250 uses the 100 and 250 stacks. Total-per-rack is the sum, so it stays consistent with the three published anchor totals. Above 250 kW the 100→250 slope continues; treat that regime as directional.

Capex adjustments

Coolant supply temperature. 45 °C removes 15% from the facility-loop slice (dry-cooler free cooling). 32 °C adds 20% (chiller required). Linear between. The adjustment appears as a separate row in the composition table so the arithmetic reconciles with the essay anchor visibly.

Two-phase multiplier. 1.35× applied to cold-plate + TIM, CDU share and controls when two-phase is selected. The model treats two-phase as economically relevant above ~180 kW/rack and disables the toggle below that; the 180 kW threshold is a model assumption, not an industry-standard boundary.

Redundancy. Base CDU count = ceil(total IT load / CDU capacity per unit). N leaves it as the base count. N+1 adds one hall-level spare CDU. 2N doubles the count. CDU capex scales with the number of installed CDUs, so N+1 adds one CDU's worth of capex and 2N doubles the CDU capex slice — redundancy is not just a spare on the shelf, it is fully-installed capacity. Real deployments may apply N+1 by row, zone or CDU group; this model uses the simpler hall-level abstraction.

Opex · formulas

Effective PUE      = base PUE − (pump_fraction_1p × 0.40)   when two-phase is selected
                   = base PUE                                   otherwise
   (two-phase drops pump electricity to 0.6× the single-phase level; that saving
    lowers effective PUE so total facility electricity falls accordingly)
Facility electricity = IT_MW × (effPUE − 1) × utilisation × 8760 × $/kWh × 1000
   (this is the ONLY electricity line; PUE is treated as inclusive of pumps + fans + chillers)
Pump electricity    = pump_fraction × IT_MW × utilisation × 8760 × $/kWh × 1000
   (sub-component of facility electricity; two-phase applies 0.6× to pump_fraction)
Non-pump overhead   = Facility electricity − Pump electricity
   (chillers, fans, controls, facility infrastructure)
Preventive maint.   = maint_pct × capex_total
Coolant refresh     = refresh_pct × 0.03 × capex_total
   (0.03 = coolant slice as fraction of stack; author estimate)
Water               = tsup < 40 ? IT_MW × 0.012 × 8760 × water_price : 0
   (0.012 m³/MWh IT is a typical evaporative rate)
Total opex          = Facility electricity + Maintenance + Coolant refresh + Water
   (pump is a sub-component of facility electricity, NOT added again on top)

Boundaries and caveats

Thermal load ≈ IT load. A simplified steady-state approximation. Pumps, fans, chiller consumption at low tsup are captured through PUE, not modelled separately.

CDU classification. Technology-side vs facility-side is a modelling choice. Other reasonable classifications put CDU on the facility-side (interface component owned by the facility MEP contractor). Treat the 48/52 split as one lens.

Two-phase vs immersion. Two-phase DTC and immersion are architecturally distinct above ~250 kW/rack, not variations of one architecture. The two-phase toggle here only sits inside DTC; immersion is out of scope.

Not modelled. Flow-rate + delta-T at the cold plate. Coolant fluid choice (water-glycol vs dielectric). White-space floor loading. Dual-loop A/B redundancy for tier-4 workloads. Component lead-time sensitivity. Any of these can move the numbers materially; treat this tool as a first-pass scenario framework, not a mechanical/electrical design study.

Change any anchor unit cost or opex assumption in Advanced to reflect a hyperscaler-specific reference design, negotiated CDU pricing, site energy price or a specific climate. See Data Centre Cooling · a double-click on Direct-to-Chip for the underlying architecture, vendor scorecards and value-migration analysis.