Data Center Life Cycle Co-Design Optimization

Abstract

Liquid cooled supercomputers dissipate tens of megawatts of waste heat through cooling plants organized as parallel subloops that serve coolant distribution units. The number of subloops and the assignment of units to them are design decisions fixed at construction, yet they have not been systematically optimized for facilities at this scale. As electricity grids decarbonize, embodied carbon becomes a larger share of facility life cycle emissions and the cost of an unnecessary subloop becomes harder to justify. We present a framework that integrates operational energy from a validated control optimizer based on sequential least squares programming, embodied carbon from a bill of materials, and expected unplanned downtime from a per subloop reliability model. The framework is applied to the Frontier supercomputer, evaluating all 611 ways of partitioning its 25 coolant distribution units into two through six subloops. The life cycle cost and carbon optimum is found at two subloops holding 14 and 11 units, achieving 3,320.7 tonnes of carbon dioxide equivalent and $3.99 million over a seven year horizon, a saving of 50.2 tonnes and $100,000 compared to built four subloop configuration. The optimum remains on the Pareto front in all 15 scenarios of a one at a time sensitivity sweep. A semi-analytical decision rule generalizes the result, predicting four subloops for Aurora, two for El Capitan, and one for LUMI. When reliability is treated as a hard constraint set by operations policy, the four subloop Frontier deployment is consistent with the constrained optimum.