Ivar Warrer-Hansen Inter Aqua Advance A/S
Transcript of Ivar Warrer-Hansen Inter Aqua Advance A/S
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
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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
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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?
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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
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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)
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Submerged stationary filter
Submerged stationary filters need to be back washed frequently
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Trickling filter
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Moving Bed Bio Reactor (MBBR)
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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
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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
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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
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New system for trout production
The Concentric Tank Concept (CTC)
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Funded by the European Union’s Seventh Framework Programme
• Varme
• Vandskifte. Frisk vand
• Alarmer.
Punkter:
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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
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Claresse, pangesius or tilapia
Examples of cheap fish in RAS
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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
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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
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