Plate heat exchanger redesign enhances data centre cooling efficiency

Power Usage Effectiveness (PUE) is a key metric used to evaluate how efficiently a data centre uses energy. Since cooling systems can represent 35–40% of total facility energy consumption, improving heat transfer efficiency is critical to lowering PUE. At the China Mobile Jinan Data Centre, plate heat exchangers play a vital role in energy-efficient cooling, making performance improvements essential for long-term sustainability.

Challenge

After five years of continuous operation, an onsite evaluation revealed declining heat exchanger performance. The terminal temperature difference exceeded 3 °C, and pressure drop had increased to 70 kPa, which are indicators of reduced thermal efficiency and higher energy demand.

To restore performance, a data-driven plate heat exchanger redesign was required. The challenge was to accurately understand real operating conditions and system behaviour. A thorough technical analysis was necessary to identify existing problems, quantify energy-saving opportunities, and establish reliable redesign criteria that would deliver measurable improvements without disrupting operations.

Solution

Alfa Laval implemented a targeted plate heat exchanger redesign program focused on restoring optimal thermal performance and improving system efficiency within the Jinan Data Centre cooling network.

The project began with continuous monitoring and in-depth analysis of operating data to establish a clear understanding of real-world system behavior and performance constraints. Based on these findings, Alfa Laval specialists developed precise selection criteria to define redesign parameters.

Using advanced engineering methods and specialized selection tools, Alfa Laval’s team provided robust technical support throughout the redesign process, by guiding the configuration of new plate arrangements and hydraulic characteristics. They ensured compatibility with the existing cooling infrastructure while addressing identified performance limitations.

Results

The completed plate heat exchanger redesign translated into a measurable PHE efficiency upgrade, delivering clear operational and energy benefits:

• 178 additional plates installed per heat exchanger to increase thermal capacity
• Reduced temperature difference across the heat exchanger
• Extended free cooling operation by 192 hours annually
• Lower pressure drop on both sides of the exchanger
• Reduced pump energy demand
• Approximately 10% electricity savings

These performance gains demonstrate how a focused heat exchanger optimization strategy can significantly improve cooling efficiency, support lower PUE targets, and reduce long-term operating costs in high-demand data centre environments.

Outlook

This project highlights how a strategic plate heat exchanger redesign can unlock meaningful efficiency improvements in modern data centre cooling systems. By combining technical analysis, advanced tools, and a focused PHE efficiency upgrade, operators can extend equipment life, reduce energy consumption, and support sustainable growth.

For China Mobile Jinan Data Centre, the redesign establishes a strong foundation for continued efficiency improvements and serves as a model for future heat exchanger optimization initiatives across high-demand digital infrastructure.