Funded by the European Union’s Seventh Framework Programme

Ivar Warrer-Hansen

Inter Aqua Advance A/S

RAS Technology

RAS tecnology -Potential for new Species

2

RECIRCULATION AQUACULTURE RECIRCULATION CYCLE Feed

Fish Waste Products: Uneaten Feed Faeces Ammonia + Urea

Water Oxygen

Mechanical Filtration Biological Filtration

Pumping Station

Energy

Heat

Principle lay-out of RAS

Inlet channel

Decentralized degassing

Centralized degassing

External extra tanks

CLEARWATER Bioreactors

Mechanical Filtration

Sludge sedimentation & effluent denitrification

Oxygen by LHO and

Without a well functioning bio filter, it doesn’t matter how

well other things function in a RAS – it will never be a success

The bio filter is the heart of a RAS

5

Limiting factors for nitrification:

• Low oxygen levels • Excessive build-up of bio film thickness, i.e. leading

to diffusion limitations of oxygen into the bio film and metabolic exhausts out, i.e. CO2 and anaerobic gasses

------------------------------------------------------------------ • pH outside optimum for nitrifying bacteria (7-7.8) • Low temperatures • Low substrate levels (total NH3/NH4 < 5 mg/l)

Of these, bio film thickness is the most important thing in achieving high rate of nitrification and stable

conditions in the bio filter:

In other words: to have Bio Film Control is the key

How does a bio film develop?

8

Stages of bio film system development

Stage 1

Fig. 4а. Stage 1. Adaptation of cells to the carrier surface

С – carrier; S – substrate; l – distance from the surface of the carrier;

1- swimming cells (suspended cell culture); 2- adhered cell

• Start of the stage: cell adaptation

• End of the stage: single attached cells

S

0 l

S

0

C 1 2 Oxygen level

Stages of bio film system development

Stage 2

Formation of cell monolayer

Fig.4b. Stage 2. Formation of cell monolayer

3 - adhered cells enveloped by exopolysacharides

• Start of the stage: single attached cells;

• End of the stage: mono cell layer.

l

S

0

S C

0

3

Stages of bio film system development

Stage 3

Bio film structure formation

Fig. 4 c. Stage 3. Formation of the bio film structure. First critical thickness of the bio film - δ1Cr

• Start of the stage: mono cell layer;

• End of the stage: poly cell layer, first critical bio film thickness -δ1Cr.

S

l

S

0

C

δ1Cr 0

Oxygen gradient Through bio film

Stages of bio film system development

Stage 4

Stable growth of bio film system

Fig. 4 d. Stage 4. Stable bio film growth. Second critical bio film thickness - δ2Cr

• Start of the stage: first critical bio film thickness -- δ1Cr

• End of the stage: second critical bio film thickness -- δ2Cr

l δ2Cr

S

C S

0

0

Stages of bio film system development

Stage 5

Uncontrolled and unstable bio film growth

Fig.4 e. Stage 5. Uncontrolled and unstable bio film growth. Cavities formation

4 – cavity

• Start of the stage: second critical bio film thickness -- δ2Cr

• End of the stage: cavities formation

C S

S

l

0

0

4

Zero O2

Stages of bio film system development

Stage 6

Bio film destruction

Fig. 4 f. Stage 6. Bio film destruction. Third critical bio film thickness- δ3Cr

5 – detached part of the bio film structure This when a stationary filter has to be back washed.

• Start of the stage: cavities formation

• End of the stage: detachment of parts of bio film volume

C S

S

δ3Cr l

0

0

5

Stages of bio film system development

Stage 7

Restart of new bio film formation. Simultaneous realization of all the stages.

Fig. 4 g. Stage 7. Restart of new bio film formation

• Start of the stage: cavities formation

• End of the stage: detachment of parts of bio film volume

C

S

l 0

0

5

1 2

3

4

6

S

1 - swimming cells (suspended cell culture)

2- adhered cell

3 - adhered cells enveloped by exopolysacharides

4 - cavity

5 - detached part of the biofilm structure

6 - new attached cells

Bio Film Control is avoiding going beyond stage 4 in the defined bio film development stages

INTER AQUA ADVANCE A/S

Stages of bio film system development

Stage 4

Stable growth of bio film system

Fig. 4 d. Stage 4. Stable bio film growth. Second critical bio film thickness - δ2Cr

• Start of the stage: first critical bio film thickness -- δ1Cr

• End of the stage: second critical bio film thickness -- δ2Cr

l δ2Cr

S

C S

0

0

The most used bio filter concepts in European RAS:

• Submerged stationary bio filters

• Trickling filters

• Moving Bed Bio Reactors (MBBR’s)

18

19

Submerged stationary filter

Submerged stationary filters need to be back washed frequently

20

Trickling filter

21

Moving Bed Bio Reactor (MBBR)

22

Biofilm thickness

120 µ

50 µ

Back washing needed

optimal

Trickle filter

MBBR

Back washing

Back washing

Biofilm control

C S

S

δ3Cr l

0

0

5

Bio Film Control

• Moving bed

• Trickling filter

• Stationary submerged filters

24

Potetial for RAS production in Czech Republic:

1. Is it for domestic or export market? If we assume domestic market:

2. Is it to supplement popular fish already produced for domestic market

3. Is it to substitute imports

4. Is it to introduce and market new fish into domestic market

5. Saltwater species not possible in Czech Republic

25

Common fish species produced in freshwater RAS in Europe

Low cost fish species:

• Tilapia

• Claresse (catfish hybrid)

• Trout

Potential for Czech

Republic

High cost fish species:

• Salmon (in freshwater)

• Sturgeon

• Pike perch

• Eel

26

New system for trout production

The Concentric Tank Concept (CTC)

27

Funded by the European Union’s Seventh Framework Programme

• Varme

• Vandskifte. Frisk vand

• Alarmer.

Punkter:

30

Concentric tank concept savings compared to standard RAS:

• Shared walls between tanks and water treatment system

• Easily erected on flat concrete floor

• No expensive concrete construction (pump sumps, bioreactor sumps etc.

• No expensive underground piping

• Very low energy consumption

• Capital costs € 3.60 per kg annual production for 300 tons Trout unit ~ € 1,080,000

• 1.3 kW per kg for trout production

31

Claresse, pangesius or tilapia

Examples of cheap fish in RAS

32

GO-2000 key data Module Footprint: 2.222 m2 (69,65 x 31,9 m LxW) Maximum Feed Capacity: 4500 kg/day (+ 20% safety margin) Water Flow Rate: 2,1 m3/s Tank Water Exchange Rate 3,6 times/hr (16 minutes residence time) Tank Volume 30 tanks, 70 m3 each = 2100 m3 production volume CLEARWATER Bioreactor Volume 452 m3 @ 62 % filling rate Mechanical Filtration: 5 x 60-micron drumfilters Main Pump: Lykkegaard, 4 x 400/500, 500 L/s, 4 duty Oxygen Supply Decentralized Low-Head Oxygen supply Fine Filtration & UV Treatment Optional - not normally supplied for Tilapia/Claresse/Pangasius Automatic pH Control Type IWAKI Power Consumption: Installed Total: 270 kW Average consumption 187 kW,

GO-2000 DATA

PRELIMINARY BUDGET

BUDGETARY PRODUCTION COSTS (based on European prices)

INVESTMENT 2,7 MIL €

Description Claresse® Pangasius growout

Annual Production 2000 tons/year 1500 tons/year

Production Sizes 50-1100 g 50-1100 g

Capital Costs 0,08 €/kg 0,11 €/kg

Fingerlings 0,08 €/kg 0,08 €/kg

Feed 0,48 €/kg (FCR = 0,75) 0,85 €/kg (FCR =1)

Water/Energy/Oxygen 0,19 €/kg 0,25 €/kg

Capacity Costs 0,09 €/kg 0,12 €/kg

Miscellaneous 0,08 €/kg 0,11 €/kg

Total Production Cost 1,00 €/kg 1,52 €/kg

The investment costs break down to app. 60% equipment and 40% concrete & building. Of the 40%, IAA assumes a reduction in cost by local contractors of 50%.

Salmon production

An example of a 5,000 tons per annum unit

35

Pre- growout module 3 growout modules

Main CAPEX headings

Preparations and licenses € 520,000

Pre-grow-out system € 7,201,479

3 x grow-out € 23,162,390

Inlet pumping station, water treatment € 250,000

Waste management € 1,200,000

Vehicles € 298,900

Fencing infrastructure, staff facilities € 480,000

Total € 33,112,769

OPEX: Costs € €/kg % NOFIMA €/kg

Smolt purchase 1,320,000 (0.26) (10.3) ( 0.21)*

Fish feed 7,609,840 (1.52) (59.4) (1.06)*

Salaries 640,000 (0.13) ( 5.0) (0.21)*

Office up keep 50,000 (0.01) (0.39

Engineer 50,000 (0.01) (0.39)

Legal, accounts etc. 100,000 (0.02) (0.78)

Oxygen supply 419,184 (0.08) ( 3.3) (0.084)*

Power 1,181,549 (0.24) ( 9.2) (0.18)*

Fish health 200,000 (0.04) ( 1.6) (0.03)

Chemicals 150,000 (0.015) ( 1.2) (0.008)

Insurances 371,200 (0.07) ( 2.9) (0.007)*

Maintenance 220,000 (0.044) ( 1.7) -

Misc. waste management, office 500,000 (0.10) ( 3.9) -

Total costs before financial costs 12 ,811,773 (2.56) (100)

OPEX......continued

• Cost per kg whole weight before depreciation and financial costs: € 2.56

• Depreciation, 15 years: € 0.44

• Financial costs, 5.5% interest – 15 years: € 0.62

• Total production costs per kg whole weight: € 3.62

• Total cost for Head on Gutted (HOG) with 88% yield: € 4.12

• Cost of processing, freight: € 0.72

• Total Cost to market HOG (volume of 4,400 kg): € 4.84

Thank you for your attention

41