Data Centre Cooling Solutions

Data centres are the backbone of the digital economy — and cooling is the backbone of data centre operations. As rack densities rise with AI and high-performance computing, and as sustainability targets tighten, the choice of cooling technology has never been more critical.

Air cooled heat exchangers offer data centre operators a proven, water-free solution for heat rejection and free cooling applications. At Spiro-Gills, we have been designing and manufacturing these systems since 1946, bringing 80 years of heat transfer expertise to the evolving demands of modern data centre infrastructure.

Based in Stafford, UK, we are the only UK manufacturer of welded finned tube and a leading producer of air cooled heat exchangers for industrial applications worldwide. Our ASME U certified, ISO 9001:2015 accredited manufacturing facility delivers custom-engineered cooling solutions that combine reliability, efficiency, and environmental responsibility.

Why Data Centre Cooling Matters

Equipment Protection and Reliability

Servers, storage systems, and networking equipment operate within narrow temperature bands. Excessive heat reduces component lifespan, increases failure rates, and can cause catastrophic downtime. The ASHRAE (American Society of Heating, Refrigerating and Air-Conditioning Engineers) recommends inlet temperatures between 18°C and 27°C (64.4°F to 80.6°F) for data processing equipment.

Energy Consumption

Cooling typically accounts for 30-50% of a data centre's total energy consumption. As facilities expand and rack densities increase, cooling efficiency directly impacts operational costs and carbon footprint. The industry metric Power Usage Effectiveness (PUE) — the ratio of total facility power to IT equipment power — is heavily influenced by cooling system efficiency.

Sustainability and Environmental Impact

Water consumption for cooling is increasingly scrutinised, particularly in water-stressed regions. Traditional cooling towers can consume millions of litres of water annually. Air cooled heat exchangers eliminate this consumption entirely, supporting sustainability goals and regulatory compliance.

Data Centre Cooling Technologies

Air Cooling (CRAC/CRAH)

Computer Room Air Conditioning (CRAC) and Computer Room Air Handlers (CRAH) units provide direct air cooling for data halls. These systems typically use chilled water or refrigerant-based cooling.

Liquid Cooling

Direct-to-chip and immersion cooling systems bring coolant directly to heat sources, enabling higher rack densities. These systems require heat rejection equipment to remove the captured heat.

Free Cooling (Economiser)

Free cooling uses ambient air or water to cool process fluids without mechanical refrigeration when conditions permit. This approach can reduce cooling energy consumption by 30-70%.

Heat Rejection Systems

All mechanical cooling generates heat that must be rejected to the environment. Air cooled heat exchangers provide water-free heat rejection, eliminating the need for cooling towers.

Air Cooled Heat Exchangers for Data Centre Cooling

Air cooled heat exchangers provide heat rejection without water consumption, using ambient air to cool process fluids. For data centres, they serve multiple critical functions in the overall cooling strategy.

How Air Cooled Heat Exchangers Work

Air cooled heat exchangers transfer heat from a process fluid (typically water or glycol) to ambient air:

1. Hot fluid from the data centre cooling system enters the heat exchanger
2. The fluid flows through tubes with external fins that increase surface area
3. Fans draw or force ambient air across the finned tubes
4. Heat transfers from the fluid to the air
5. Cooled fluid returns to the data centre cooling system

The finned tube design is crucial — fins dramatically increase the air-side surface area, compensating for air's lower heat transfer coefficient compared to water.

Forced Draft vs Induced Draft Configurations

Forced Draft

• Fans blow air upward through the heat exchanger bundle
• Easier maintenance access to fans and motors
• Better accommodation of hot air recirculation prevention
• Generally lower fan power consumption

Induced Draft

• Fans draw air upward through the bundle
• More uniform air distribution across the bundle
• Reduced risk of hot air recirculation
• Better performance in high ambient temperatures

Advantages of Air Cooled Heat Exchangers for Data Centres

• Zero Water Consumption: Eliminates water supply dependency, treatment, and discharge management
• Lower Maintenance Requirements: Focus on fan motors, bearings, and fin cleaning only
• No Cooling Tower Required: Reduces capital and operational costs
• Regulatory Compliance Benefits: Simplifies permits, inspections, and legionella risk management
• Suitability for Free Cooling Applications: Enables energy savings for much of the year

Applications in Data Centre Infrastructure

• Heat rejection from chilled water loops
• Free cooling systems
• Supplementary cooling for high-density racks
• Edge data centre cooling

Free Cooling with Air Cooled Heat Exchangers

Free cooling — also called economiser cooling — uses ambient air or water to cool data centre process fluids without mechanical refrigeration. Air cooled heat exchangers are the primary enabling technology for water-side free cooling.

How Free Cooling Works

1. Warm water from the data centre cooling system flows to the heat exchanger
2. Ambient air cools the water as it passes through the finned tubes
3. Cooled water returns directly to the data centre cooling system
4. Chillers remain off until ambient temperatures rise above the free cooling threshold

UK Climate Advantages

• Cool ambient temperatures for significant portions of the year
• Moderate summer temperatures (typically below 30°C)
• High number of free cooling hours annually

Energy Savings Potential

Free cooling can reduce data centre cooling energy consumption by 30-70%, depending on system design and climate. For a 1MW data centre, this can translate to hundreds of thousands of pounds in annual energy savings.

Spiro-Gills Air Cooled Heat Exchangers for Data Centres

UK-Manufactured Air Cooled Heat Exchangers

• 80 years of continuous heat exchanger manufacturing
• ASME U certified quality management
• BS EN ISO 9001:2015 accredited processes
• Full material traceability
• Comprehensive testing and inspection

80 Years of Heat Transfer Expertise

Since 1946, we have designed and manufactured heat exchangers for demanding industrial applications. This heritage informs every data centre cooling solution we produce — proven reliability refined over decades.

Custom Design Capabilities

• Thermal duty calculations and equipment sizing
• Customised finned tube configurations
• Optimised fan and motor selections
• Structural design for specific site conditions
• Corrosion-resistant coatings and materials

HTRI Thermal Design Software

We utilise HTRI (Heat Transfer Research, Inc.) software — the industry standard for heat exchanger thermal design, enabling rigorous calculations and performance validation.

Spiro-Gills Product Capabilities

• Applied finned tube technology (aluminium or steel fins)
• Welded finned tube technology (HFRW fins)
• Flexible material options for tubes, fins, headers, and frames
• Corrosion-resistant coatings for harsh environments
• Quiet operation designs for sensitive environments

What Spiro-Gills Manufactures

• Air Cooled Heat Exchangers: Complete in-house manufacture and support
• Shell & Tube Heat Exchangers: ASME standard certified
• Air Dryers: Compressed air and process gas drying solutions
• Economisers: Waste heat recovery and boiler efficiency
• Welded Finned Tube: Only UK manufacturer of HFRW finned tube

Engineering and Technical Support

• Thermal duty calculations
• System integration support
• Performance optimisation
• Installation guidance

Data Centre Cooling Trends

• AI and high-density computing challenges
• Sustainability and carbon reduction targets
• Water conservation requirements
• Edge computing and distributed data centres

Frequently Asked Questions

• Do data centres need cooling? Yes — essential for operation and equipment safety
• How is a data centre cooled? Air cooling, liquid cooling, free cooling, or combination systems
• How are UK data centres cooled? Chilled water systems with air cooled heat rejection, utilising free cooling extensively
• What is free cooling in data centres? Using ambient air/water to cool process fluids without mechanical refrigeration
• What is an air cooled heat exchanger? Device using ambient air to cool process fluids via finned tubes
• How much water do air cooled data centres save? Eliminates water consumption compared to cooling towers entirely
• What is the lifespan of an air cooled heat exchanger? Typically 20-30 years with proper maintenance
• Can air cooled systems handle high-density AI workloads? Yes, for heat rejection from chilled water loops, often supplementing liquid cooling

Why Choose Spiro-Gills for Data Centre Cooling

• UK manufacturing for shorter lead times and supply chain security
• 80 years of expertise in heat exchanger design
• Only UK manufacturer of welded finned tube
• ASME U certification
• Custom engineering for client-specific requirements
• Sustainability focus: zero water consumption and free cooling
• Comprehensive support from design through commissioning

Contact Our Data Centre Cooling Specialists

Discuss your data centre cooling requirements with our technical team. Whether you need air cooled heat exchangers for heat rejection, free cooling systems, or complete cooling solutions, we provide engineered systems that meet your performance, efficiency, and sustainability goals.

Phone: +44 (0) 1785 254 554
Email:

Spiro-Gills Thermal Products Ltd
St Albans Road, Stafford, ST16 3DR, England