Ivar Warrer-Hansen Inter Aqua Advance A/S

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  • Funded by the European Unions 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 doesnt 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. 4. Stage 1. Adaptation of cells to the carrier surface

    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 - 1Cr

    Start of the stage: mono cell layer;

    End of the stage: poly cell layer, first critical bio film thickness -1Cr.

    S

    l

    S

    0

    C

    1Cr 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 - 2Cr

    Start of the stage: first critical bio film thickness -- 1Cr

    End of the stage: second critical bio film thickness -- 2Cr

    l 2Cr

    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 -- 2Cr

    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- 3Cr

    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

    3Cr 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 - 2Cr

    Start of the stage: first critical bio film thickness -- 1Cr

    End of the stage: second critical bio film thickness -- 2Cr

    l 2Cr

    S

    C S

    0

    0

  • The most used bio filter concepts in European RAS:

    Submerged stationary bio filters

    Trickling filters

    Moving Bed Bio Reactors (MBBRs)

    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

    50

    Back washing needed

    optimal

    Trickle filter

    MBBR

    Back washing

    Back washing

    Biofilm control

    C S

    S

    3Cr 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 Unions 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