wtfrank :
OK point taken about the claimed TDP not being at 100% load. What are your views on the Heligon HE02 which claims to handle 95W fanless? Its kind of hard to compare if Heligon claims it can disippate 95W (but presumably in practice does a bit worse), while Intel claims the 4770K emits 84W (yet if thats not at 100% then it practice it will sometimes create more heat). EDIT: Nvm, just found the comparison at SPCR between HE02 and the CR-95C - CR95C is better.
And BTW I am running a fairly quiet machine - SSD, fanless GPU, fanless PSU. Just one slow case fan. I'm hoping I can achieve something similar with my Haswell upgrade.
As you can see in the review, the HE02 fails after 9mins continuous load. And even the CR95C shows +62c thermal rise (that's +62c rise
above ambient 20-35c case temp, ie, 82-97c load). That's a little too high for comfort. And that's just after 15mins, imagine compressing video for say 6hrs. The problem with Haswell is that under load, the IVR's rather "helpfully" add an extra +0.1v to the CPU when detecting any AVX instructions (which is the last thing you want in a silent PC rig).
If you haven't bought anything yet, I'd suggest an Ivy Bridge i3-3570 (non-K as there's no way you're going to OC on a passive cooler) and then undervolt it as far as your can. On average, you should be able to run the CPU around -0.10 to -0.15v which at stock 3.4GHz should knock off about 10-18w of heat. eg, 77w i5-3570 may in reality run at say 68w. If you undervolt it, you could get that down to 50-58w. If you're really lucky and get a good CPU with a very low VID (stock voltage), and you manage to heavily undervolt it by -0.15v, you could even get it down to below 50w full load. My i3-3570 could run at 3.8GHz (a mild overclock) at just 0.92v with effectively only 40w TDP. Each CPU is different though.
I suggest Ivy Bridge because they do run cooler under load than Haswell's and they don't arbitrarily add +0.1v when they feel like it. They are definitely more "silent PC" friendly in the "voltage is stable under load" sense. Other guaranteed success option of course, is an i3-3240/3250 (3.4-3.5GHz 55w dual core) that could potentially be undervolted down to approaching 30w (from its official 55w).
To be honest though, if you already have one slow sub 700rpm case, fan, you may as well stick one on the CPU because "parallel fan" noise doesn't scale badly at all. Eg, if one 10db fan = 10db, then 2x 10db fans may only = 11db, which is barely imperceptible at typical 1m distance from case on floor, but is worth -30c on a passive cooler. I'm something of a silent pc enthusiast myself and looked at an all passive build but instead settled on an ultra quiet 12-15db 700pm fans instead (cheaper & cooler operation, but still ridiculously quiet). I feel a lot more comfortable with s 55c CPU than a 90c one and there's barely 5db difference.
Edit: There's also BIOS settings to play around with. Eg. the
Noiseblocker S1 fan can go as low as 250rpm (that literally is inaudible from 1m away). You could set your BIOS fan control speeds to say 50% (on a 800rpm fan) = around 350rpm from CPU temps 30-70c, then maybe set a "high" speed of 70-75% (700rpm) for 80c, would result in "virtually passive" during normal use, but an extremely quiet active cooling to prevent it overheating under load where +90c temps are a bad idea in general.