recirculation systems for fish and shrimp with integrated hydroponics
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By Llyn Aquaculture LtdTRANSCRIPT
Recirculation Systems for fish and shrimp with integrated hydroponics
(Aquaponics)
• Candidate Species• System Design and function• Snippets of economics (dangerous without looking at all
details of each situation)• Possibilities to integrate with hydroponics• Aquaponics – Fish farming with a bit of veg’ on the side
Recirculating Aquaculture Systems - RAS
Llyn Aquaculture Ltd
Established Summer 1999 at Afonwen Farm, Pwllheli, Gwynedd, N. Wales Marine and Freshwater Recirculation
Systems Demonstration Farm Design and Consultancy Supply and installation R & D projects
Recirculation Systems – Llyn Aqua Marine systems Brackish water Fresh water
Turbot pilot system - Marine
Llyn Aqua Pilot System.
Design and supply Intensive Fish Productionsystems – research, pilot and commercial.
High Value species Turbot Sole Shrimp Sea Bass Eels Fresh water Perch Arctic Charr
•Low Value (high volume)•Barramundi (Asian Sea Bass)
•Tilapia
General Design Considerations
Design
Choice of Species
Location
Temperature
Biosecurity
SalinitySales stratedgy
Production capaci
Water IssuesAvailability / discharge
Financial IssuesGrantsInvestementSelling priceProduction costsConstruction costsLand costBorrowing cost
Reasons to Recirculate
Limited Water Temperature Control Salinity Control (specialised) Disease control Increase production per unit area / volume
To boldly grow fish where no fish has been grown before
Recirculation System Complexity vs % daily exchange
2,400% 1,000 % 500% 100% 50% 20% 10% 5%
Flow Through Re - Use
Oxygen + AerationSimple Solids Separation
Biological FiltrationMechanical Filtration
Fine Filtration (< 50 micron)UV
Degassing and pH controlFoam Fractionation
DenitrificationOzone
Sedimentation
% of tank volume exchanged per day
Design. Each situation is unique and must have custom design based on tried and tested technology. Water Exchange (new water) Mechanical Filtration – Coarse and fine particle removal
Biological Filtration UV and Ozone Gas Exchange / Oxygen / CO2 /pH Salinity
Water Movement – pumping and pipes Protein skimming / foam fractionation
Reduced water exchange to < 50% vol per day
Fine particle filtration (< 50 micron) – side stream UV ‘sterilisation’ – side stream Foam fractionation (Protein skimming) Ozonation – requires strict control – only to
be used on very ‘closed’ intensive systems. pH Buffering
Pros and Cons - Recirculation Total Control Water Quality Temperature Oxygen Flow rates Disease Control High Productivity Low Labour Effluent Control
High Cost!?
Cons
More Pros•Enables aquaculture to take place where otherwise not possible•Low food miles•Freshness
E.g. Recirc’ vs Flow Through with 5 m3/hr water (120 m3/day)
Flow through – 10 m3 tank vol – 1 tpa production
Recirculation 10 % volume exchanged per day – 1,200m3 tank vol – 120 to 200 tpa production depending on species.
Minimal Water intakee.g. 20 tonnes Sea Bass pa
Fine Filtration – 5 micron
High UV dose - Filter and UV rated 4m3/hr – used at –10 m3 per day.
Pathogen Free
Pumping once per month from sea to storage tank.
Easy temperature control
Species – with system examples Marine (or
Brackish) Turbot Sea Bass Sole Shrimp Barramundi Sea Trout Halibut (cold)
Fresh Water (or Brackish)
Arctic Charr
Perch
Barramundi
Tilapia
Sturgeon
2000 – 2002, 1st sea bass RAS in UK, 20 tonnes per annum (300m2 building)
Purging tank (clean water)
Total water volume of 160 m3 = 125 Kg / m3 / yr
Water Exchange average 10% / day = < 300 l/ kg fish
Sea Bass•Temperature (opt) 18-25
•Salinity 10-40
•Growth to 400g <1 yr
•Growth to 800g Av’ 1.5 yr
•FCR 1.3 to 1.5
•Density - up to 100 Kg/m3
Pros•Temperature
• Well known
• Sales volume
•Fry
Cons•Delicate
•Aggressive
•Competition
•Low price
•£4.50 / Kg
•Large volume
Ongrowing System. Sea Bass 160 Cubic metres.-Llyn Aqua Pilot - 20 tonnes per year = 125 Kg / m3
per year!
Price Drop
00-02 - £5.5 to £6.5/ kg ex farm
03 < £4.50 delivered UK from Greece
2009 – Euro 3.00 per Kg (Greece, Turkey)
Now need to sell at £4.00 to £4.70 per Kg ex farm UK
Turbot and Dover Sole
400 m3/ hr filter in 60 tonne pa charr unit
200 m3 / hr filter in 25 tonne per annum perch unit.
Note purge tanks behind.
•Turbot Ongrowing. Low energy Low volume shallow tanks
Low FCR.
0.8 up to 1 Kg
1.0 up to 1.5 Kg
Turbot. 1.5 - 2.0 Kg in 18 - 24 months from egg. 12 – 18 moths from 5-10g fry
•Temperature (opt) to 500g 22 to17
•Temp’ (opt) 0.5 – 2Kg 17 to14
•Salinity 10-37
•Growth to 1 kg 1 to 1.5 yr
•Growth to 1.5 Kg 18 – 24 mths
•FCR 0.9 to 1.1
•Density - up to 40 Kg/m2
•At 30 to 40 cm deep = 100-120kg/m3
Pros•Temperature*
• Luxury Niche
•High Value £6.0 - £7 per Kg
•Higher if sell direct
Turbot Shallow Raceway system
Turbot in Shallow raceway recirculation system. 20 Kg per m2 (7 cm deep) = 285 Kg / m3
Approx’ 600 kg / m3 / year production !
At 10% exchange per day = 60 litres per Kg produced.
(Sea bass = 300 l/kg)
Solids Removal Prevents overloading of bio-filter and build up of
anoxic sludge.Removal down to 50 microns. Sedimentation – Simple / low flow / load Moving screens – Drum or Conveyor beltRemoval below 50 microns Fixed bed – Pressurised sand or beads Fixed bed – slow up-flow / submerged media Both require periodic backwashing.
Example 50 tonne perch farm – Ireland, 2 modules of 25 tonnes per annum
12.000m
0.400m
0.800m
1.850m
0.150m
2.650m
RSJ
1.936m
1.900m
UV
0.800m
2.8
00m
Flui
d Be
dUp
flow
2.950m 3.600m
1.800m
2.250m
1.500m
2.000m
4.0
00m
3.850m
0.23
5m
0.58
5m
4.000m
3.850m 0.300m
6.000m 6.021m
Water filtration area
0.400m
0.800m
1.850m
0.150m
2.650m
RSJ
1.936m
1.900m
UV
0.800m
2.800m
Flui
d Be
dUp
flow
2.950m 3.600m
1.800m
2.250m
1.500m
2.000m
4.000m
3.850m
Concrete drain sumps
0.235m
0.585m
4.0
00m
3.850m
0.30
0m
6.000m 6.021m
200mm 8.500m
Pink pipes above ground until this point 160mm pipe under tanksGreen pipe shows waste water out from sumps
Waste pipe between the two 400 mm pipes here
2.760m
47.500m
Solids removal – Moving mesh with backwash spray - Conveyor or Drum filter.
Drum Filter – High flow / low headOnly 2 – to 5 cm head loss
Mechanical Drum Filter with vortex separator
0.800m
1.850m
0.150m
2.650m
1.936m 1.900m
UV
0.800m
2.8
00m
2.950m 3.600m
1.800m
2.250m
1.500m
2.000m
4.0
00m
3.850m
0.23
5m
0.58
5m
4.000m
3.850m 0.300m
6.000m 6.021m 8.500m
2.760m
Biological Filtration
Low Head Pumps
Biological Filtration
30 tonne per annum system (European Perch) Low Head Llyn Aqua pumps- 6 of 100 m3/ hr @ 1m head. 0.75 KW each.
Trickle Filter & Low Head (1 to 1.5m) Axial Flow pumps
(pre 2000 technology) 8 + 2 temp monitoring.£9,000 in 1999
Llyn Aqua Sensor Monitor (LASM)
e.g 8 oxygen - £4,000 Today
Monitoring and control -4 x LASM units on network – with phone dialer
•2 x 25 tonne systems -
•24 Oxygen
•2 Temp
•6 float switch level alarm
•2 pressure switch – Oxygen
•Power failure
•WWW – viewed and controlled from anywhere on net
Dover Sole – The Holy Grail? Very High Value Very difficult broodstock Slow Growth – 300 –
400g in 1 year (30% of stock)
Feed related – Do not thrive on fish based diet
Stacked Shallow Raceways
Arctic Charr• Temperature (opt)
12-17
• Salinity 0 - 37
• Growth to 1Kg <1 yr
• Growth to 1.5Kg 17 mth
• FCR <1.0
• Density - up to 100 Kg/m3
Down Side
Price drop
2006 £5.30
2009 Euro £4.50
Production cost of £3.5 / Kg.
£3.0 / Kg at over 200 tonnes.
Fresh water – brackish - marine
Relevant Example - 60 tpa Arctic Charr farm - Ireland.
Bore hole water - 12 Deg. C 50 % exchange per day (300m3) Circulation up to 2.5 x per hour through
tanks = 60 times per day New water = 0.8 % per cycle Rate of recycling = 99.2%
60 Tonne per annum Charr. Nursery system – 8 of 15 m3
Grow Out System – 4 of 100 m3
Fish More relaxed at high density – up to 80 Kg/m3 in Nursery and 100 Kg / m3 in Grow out tanks –10 tonnes per tank!
Large tanks – more economical from Concrete. < 10 m3, GRP or HDPE.
•Halibut Raceways – Norway
•Flow Through farm
•Failed due to disease
Total Flow 1000 m3 / hr
Crystal clear purging system – 1 week prior to slaughter. Empty guts and remove any ‘off flavour’
Low visual Impact - no more than mushroom farm.
Fresh Water European Perch.•Temperature (opt) 18-25
•Salinity 0 - 10
•Growth to 200g 10 mths
•Growth to 400g Av’ 12 - 18
•FCR 1.3 to 1.5
•Density - over 100 Kg/m3
•Very Niche market - Switzerland
Concrete block – 50 Tonne Perch, Ireland
Tropical Shrimp (white)L. Vannamei•Temperature (opt) 26 - 30
•Salinity 3 - 40
•Growth to 20g 4.5 mths
•£8 (20g) to £12 (25 – 30g) / Kg
•FCR 1.0 to 1.3
•Density - 7 to 10 Kg/m2
•Niche market – top quality, never frozen, super fresh, live, no preservatives, harvest and deliver same day.
•Not to compete with bulk frozen imported
Super Intensive ‘ICE’ (Indoor Controlled Environment) shrimp
Up to 8 Kg / m3
28 Deg C
25 Kg / m2 / yr output
Salinity 5 to 40 ppt
‘ICE’ Shrimp – Indoor Controlled Environment
PROS•Fast turnover
•2.5 cycles per year
•25 Kg / m2 tank per year
•High price - £8 + /kg ex farm
CONS•High space required
•High Temp
•Cheap competition
High space means high construction cost – 100 tonnes - £1.25 million
Tilapia – The Chicken of the ‘sea’PROS
•Fast turnover (<10 mths)
•>200 Kg / m3 / year
•Salinity 0- 5ppt
•Some strains – full Sea water
•Low protein plant based feed –35%
•Production cost ca. £4.0/Kg
CONS
•High Temp 26 - 30
•Cheap competition
400 tpa farm – ca £1.45m
Tilapia competition < £1.0 / Kg
Aquaponics -Plenty of freshwater examples on the internet
Silver Carp + Rice
‘Backyard’ aquaponics
Llyn Aqua Integrated System – 2001, EU funded R & D programme - GENESIS
Solids separation
Fish Rearing Systems
Sludge
Primary SettlerSecondary Settler
Aerated LagoonRetention time
Surplus water
Waste Water+
Discharge
300m3 300m3
Floating
Sinking
40 m30.3m deep 2m deep2m deep
3.032m
Septic tank
Sedimentation, worms?Periodic pumping
Phytoplankton
30 days
RT = 4 days
Phytoplankton / Artemia
New
Salicornia + Clams ?
New Area
To Natural Wetland
or recycled back to fish
Spread on Land
Sand Gravel with simulated tide
Lly Aquaculture - Cold Climate Integrated System
12.000m
10.000m
??
Ca. 5 m3 per day??
3.000m
10.000m
Nutrient Assimilation - Clean discharge.
Mean water quality During May May Water Quality (Mean of Weekly samples)
0
0.1
0.2
0.3
0.4
0.5
0.6
Position
ppm
Nitr
ite &
Nitr
ate
02468101214
ppm
Pho
s &
Am
mon
ia
Nitrite 0.28 0.001 0 0 0Nitrate 0.55 0.12 0 0.05 0.03Ammonia 8.3 2 1.8 1.1 0.5Phosphate 11.6 10.6 5 8.1 6.1
2 3 4 5 6
Manila (Sept) Native (Sept)
Phytoplankton
Euglena Spp. High Nutrient -
Brackish
Phytoplankton
Prasinophyte Platymonas Spp.??)
Rotifer Population DensityRotifer density 2003 / 2004
0
20
40
60
80
100
120
140
08/04
/2003
22/04
/2003
06/05
/2003
20/05
/2003
03/06
/2003
17/06
/2003
Pos' 3Pos' 4Pos' 5Pos' 6Harvest - mPos 5. 2004
Manila Clams Native Clams
Early Salicornia (Samphire) trials
Salicornia – Species selection, development of ‘strain’, and seed production.
Replicated density trialsUp to 10 Kg / m2 per year
Wholesale - £5 per Kg
Western Australia. Barramundi and peppers.
Abalone - Fish/shrimp - plankton
Abalone - Shrimp - Sea Weed (Ulva)
Israel: Integrated System
Algae grown in discharge water from recirculation system
Used as feed for Abalone and Urchins
Israeli Integrated modelAbalone + Urchins
Bore hole sea water
Intensive sea bream RAS
Nutrient rich water
Algae
Algae as feed for Abalone
Salicornia beds