> full-text search of 20MM PDFs at our traffic levels is expensive to operate
Assuming you convert them to text once, index them, and put them in a standard FTS engine, I'd guess it is on the order of 100GB-1T of text (max), plus some more for the index (basing these estimates with my experience text mining PubMed Central and MEDLINE). So it can all fit on a pretty standard server. Maybe at 100 req/s it would take a few. Yes, you'd want replication.
The number of servers required to get good latency FTS is the part of this that I'm least familiar with. Anyone have a ballpark, given these estimates, on what kind of hardware would be required? (I could easily be wrong, and indeed this is very expensive. If so, I'd be curious about ballpark numbers)