I mainly use FDS with building models that consider smoke as the primary objective and have between 1 and 10 million cells. I use dual processor workstations (HP z620) with xeon cpu's (E5-2680v2) and ecc ram. I'm not sure if the ram speed affects the speed very much, but I don't have different ram systems that are comparable, so can't say for sure. I can recommend buying used xeon processors, they use more power than the new ones, but have still have decently high frequency when all cores are working 100% and are much cheaper than a new cpu.
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When I set up my cluster I was faced with this very problem. I wanted fast model processing at a budget price.
A really good place to start is to read the FDS Users Guide. This will advise minimum hardware requirements and matters that will likely affect processing speed.
NIST use Intel compilers and these are optimized for Intel hardware. While there are other processor manufacturers and compilers, you might reasonably expect to minimize grief and optimize performance by sticking to Intel hardware. In my experience, for FDS, the GNU compiler works but is slower than Intel, and may create all manner of issues that are best avoided entirely.
For an Operating system I would recommend a Linux flavor. Linux is cheap (or free), well supported, and has significantly less processor burden than Windows. Linux boots in seconds while Windows takes several minutes (there are exceptions such Surface Pro which appear to use SRAM or EEPROM resident software). Yes, I do run FDS on Windows, but primarily for building models using PyroSim, and for optimization. My commercial models are run on my Linux cluster.
The major processing component of any FDS model is the cpu burden (over other stuff like RAM speed and size, disk access and communications). While Xeon, and more recent processors may have many cores, large cashe, fast bus speeds and so forth, Xeon processors are relatively slow (~2 GHz), and others throttle the clock significantly under increasing core utilization and/or temperature. You’ll need to read the CPU data sheets to understand this.
Hyper-threading is usually of no value with FDS. While you may think you have more cores, expect the model to slow down.
With any FDS model, avoid fully committing all available cores on each node. This may slow the model run-time down. This is particularly important on the Master node from where FDS is launched.
I settled on Intel I7 4097K processors with a Gigabyte motherboards. These have a stable 4.4 GHz turbo clock and, with enhanced water cooling and BIOS settings, these don’t throttle despite 100% core utilization. If necessary they will also over-clock above 5.3 GHz, but I don’t do this as a matter of course.
For expansion you will need relatively fast networking. I use Mellanox Infiniband at 40 Gbps, but 1 Gbps Ethernet is relatively standard these days and improving communication speed comes with only a few percent in model run-time performance.
I also have two I9 nodes with 10 (real) cores on my cluster. These are thermally hopeless and throttle under moderate loads or core utilization. I use these for low-burden meshes and running concurrent models. I won’t be getting any more I9’s and have contemplated changing these out for more I7’s.
Of course this is all meaningless without some form of bench-marking. If you want some relative performance measures of my cluster verses a number of others (including HPC super-computers) then link to http://fire.aquacoustics.biz/html/publications.html and download the link FDS 6.7.0 Verification Report. NIST have a number of standard speed benchmark models for strong and weak scaling and general performance. I have only recently started using these so I don’t have a meaningful history or comparative performance at this time.
So, in my opinion, get the fastest Intel processor that you can afford and use Linux.