utilization of a zero-exchange, mixed-cell raceway for marine shrimp production james m. ebeling,...

Utilization of a zero-exchange, mixed-cell Utilization of a zero-exchange, mixed-cell

raceway for marine shrimp productionraceway for marine shrimp production

James M. Ebeling, Ph.D. James M. Ebeling, Ph.D. Research EngineerResearch Engineer

Aquaculture Systems TechnologyAquaculture Systems Technology

Michael B. Timmons, Ph.D.Michael B. Timmons, Ph.D.ProfessorProfessor

Cornell UniversityCornell University

Rodrigo A. Labatut Rodrigo A. Labatut Research AssistantResearch AssistantCornell UniversityCornell University

6th International Conference on Recirculating Aquaculture6th International Conference on Recirculating Aquaculture

IntroductionIntroduction

Insatiable Demand for SeafoodInsatiable Demand for Seafood• Increasing market demand Increasing market demand • Changing MarketChanging Market• Increase Supply – Increase Supply – “global market” place“global market” place

• Decreasing PriceDecreasing Price• Sophistication of ConsumerSophistication of Consumer

• ““organic”organic”• sustainable production methodssustainable production methods• local producelocal produce



Raceways (plug flow reactors)Raceways (plug flow reactors)

Excellent footprint utilizationExcellent footprint utilization

Efficient and easy handling & sorting Efficient and easy handling & sorting

Water quality gradient (DO)Water quality gradient (DO)

Low velocity (not self cleaning)Low velocity (not self cleaning)

Application of engineering principles for Application of engineering principles for economically sustainable productioneconomically sustainable production



Circular Tanks (continuously mixed reactors)Circular Tanks (continuously mixed reactors)

Less efficient footprint utilizationsLess efficient footprint utilizations

Husbandry tasks more difficultHusbandry tasks more difficult

Good self cleaning Good self cleaning

Optimal velocitiesOptimal velocities




Mixed-cell RacewayMixed-cell Raceway

Efficient footprint utilizationsEfficient footprint utilizations

Efficient and easy handling & sortingEfficient and easy handling & sorting

Good self cleaning velocities Good self cleaning velocities

Optimal velocities for fishOptimal velocities for fish



““New Paradigm”New Paradigm”

Sustainable EngineeringSustainable Engineering

Zero-exchange Production SystemsZero-exchange Production Systems

Mixed-cell racewaysMixed-cell raceways Design and ConstructionDesign and Construction Hydraulic CharacterizationHydraulic Characterization Water QualityWater Quality Solids ManagementSolids Management Production Systems OptionsProduction Systems Options


Engineering DesignEngineering Design Mixed-cell RacewayMixed-cell Raceway


Pump

Pump

Pump Pump

Pump Pump

4” Manifold Pipe

SRTANK

Sludge Disposal

Sump &Settling w/Stirring Pump

Harvest by

screen capture

6” drain line




10 cm manifold

threaded bushing 3.18 cm by 2.54 cm with a 2.54 cm threaded plug - drilled

15 cm drain line

5 cm gate valve

5 cm unions

5 cm vertical manifold

20 ml HDPE liner 15 cm drain with 5 cm orifice

5.44 m

1.22 m

Water Depth

manometer

0.75 kW pump

check valve

top plate

Sidewall modules


ConstructionConstruction – Greenhouse – Greenhouse

16.3 m x 5.44 m x 1.22 m16.3 m x 5.44 m x 1.22 m (18 ft x 56 ft x 4 ft).(18 ft x 56 ft x 4 ft).

20 ml HDPE Liner20 ml HDPE Liner


Water Distribution SystemWater Distribution System

Sump TankSump Tank• water levelwater level• harvestingharvesting• solids managementsolids management

Water Distribution ManifoldWater Distribution Manifold


Water Distribution ManifoldWater Distribution Manifold

3” Distribution Lines3” Distribution Lines

OrificesOrifices

Vertical manifoldsVertical manifolds


Systems ManagementSystems Management

MonitoringMonitoring• Water LevelWater Level• Air PressureAir Pressure• Manifold PressureManifold Pressure• Heating Loop PressureHeating Loop Pressure• Water TemperatureWater Temperature• Air TemperatureAir Temperature• Sound LevelSound Level• PowerPowerHeat ExchangerHeat Exchanger

Propane HeaterPropane Heater


Engineering DesignEngineering Design

Tank Rotational VelocityTank Rotational Velocity

Controlled by the design of the orifice dischargeControlled by the design of the orifice discharge (inlet flux of momentum)(inlet flux of momentum)

– Orifice diameterOrifice diameter– Nozzle discharge velocityNozzle discharge velocity– Number of orificesNumber of orifices

. .


Orifice Design Orifice Design

Experimental TrialsExperimental Trials

Three Orifice – 10, 15 20 mmThree Orifice – 10, 15 20 mm

Discharge velocity held constantDischarge velocity held constant

(flow rate increased with orifice diameter)(flow rate increased with orifice diameter)


Velocity MeasurementsVelocity Measurements

SonTek Argonaut AcousticSonTek Argonaut Acoustic Doppler VelocimeterDoppler Velocimeter

3D Probe3D Probe


Hydraulic CharacterizationHydraulic Characterization

Grid Layout for one cell

0.5 m grid lines0.5 m grid linesone sample/secone sample/sec20 sec average20 sec average

Edge -2.5 -2.0 -1.5 -1.0 -0.5 0.0 0.0 0.5 1.0 1.5 2.0 2.5 Edge

Edg

e

Edg

e

2.5

2.5

2.0

2.0

1.5

1.5

1.0

1.0

0.5

0.5

0.0

0.0

-0.5

-0.5

-1.0

-1.0

-1.5

-1.5

-2.0

-2.0

-2.5

-2.5

Edg

e

Edg

e

Edge -2.5 -2.0 -1.5 -1.0 -0.5 0.0 0.0 0.5 1.0 1.5 2.0 2.5 Edge


Research ResultsResearch Results

0

5

10

15

20

25

30

35

40

45

50

55

60

65

0 5 10 15 20 25 30 35

Nozzle diameter (mm)

Ro

tati

on

al v

elo

city

(cm

/s)

10 m/s

9 m/s

8 m/s

7 m/s

6 m/s

5 m/s

4 m/s

3 m/s

2 m/s

1 m/s

Iso-curves for predicting mean rotational velocities for different nozzle diameters and discharge jet velocities.



Piezometric head required in the vertical manifolds as a function of the inlet jet velocity.


Research Application - DesignResearch Application - Design

Zero-exchange Mixed-cell RacewayZero-exchange Mixed-cell Raceway 0.5 exchange rate / hr (250 gpm)0.5 exchange rate / hr (250 gpm) 15% (35 gpm) center drains15% (35 gpm) center drains

Optimal Tank Rotational VelocityOptimal Tank Rotational Velocity Average 10 cm/secAverage 10 cm/sec Discharge Jet Velocity = 4 m/sDischarge Jet Velocity = 4 m/s Pressure Head = 1 mPressure Head = 1 m



0.50 tank exchanges per hour0.74 m3/min (250 gpm)10 mm discharge orifice1.00 m pressure head15% from center drain

1.5 kW Pumps (2 Hp)

#2 #3 #1

-2.5 -2.0 -1.5 -1.0 -0.5 0.0 0.5 1.0 1.5 2.0 2.5

-2.5

-2.0

-1.5

-1.0

-0.5

0.0

0.5

1.0

1.5

2.0

2.52 cm/sec4 6 8 10 12 14 16 18 20 22 24


Research ResultsResearch Results Mixed Cell HydrodynamicsMixed Cell Hydrodynamics

13.1

16.2

14.4

11.1

8.2

5.6

3.2

0.4

0

4

8

12

16

20

Vel

ocit

y (c

m/s

) .


Production TrialProduction Trial

Mixed-cell Raceway Production TankMixed-cell Raceway Production Tank


Water QualityWater Quality

DO Temp Salinity pH TAN NO2 NO3 Alkalinity

(mg/L) (Deg C) (ppt) (mg/L) (mg/L) (mg/L) (mg/L)

Average: 4.9 28.8 3.9 8.09 0.95 0.14 1.3 363

StDev: 1.2 1.0 0.3 0.20 0.26 0.18 0.8 53

Min: 2.3 26.3 2.8 7.67 0.47 0.004 0.2 238

Max: 6.6 30.5 4.3 8.63 1.72 1.28 5.1 450



0.0

0.5

1.0

1.5

4/28/04 5/12/04 5/26/04 6/9/04 6/23/04 7/7/04 7/21/04 8/4/04

NO

2 -

N (

mg/

L)

No Sugar!

Mixed-cell Raceway Production Tank NOMixed-cell Raceway Production Tank NO22-N-N



0

50

100

150

200

250

4/28/04 5/12/04 5/26/04 6/9/04 6/23/04 7/7/04 7/21/04 8/4/04

TS

S (

mg/

L)

Mixed-cell Raceway Production Tank TSSMixed-cell Raceway Production Tank TSS





Mixed-cell racewaysMixed-cell raceways Design and ConstructionDesign and Construction Water QualityWater Quality

Solids ManagementSolids Management Production Systems OptionsProduction Systems Options


Settling BasinsSettling Basins

Sedimentation: AdvantagesSedimentation: AdvantagesSimplest technologiesSimplest technologiesLittle energy inputLittle energy inputRelatively inexpensive to install and operateRelatively inexpensive to install and operateNo specialized operational skillsNo specialized operational skillsEasily incorporated into new or existing facilitiesEasily incorporated into new or existing facilities

18

D)(gV

2pp

s

Sedimentation: DisadvantagesSedimentation: Disadvantages Low hydraulic loading ratesLow hydraulic loading rates Poor removal of small suspended solidsPoor removal of small suspended solids Large floor space requirementsLarge floor space requirements Resuspension of solids and leechingResuspension of solids and leeching



Design to minimize turbulence:Design to minimize turbulence:

vs = 0.0015 ft/sec

Q = Flow 1 gpm

vo = 0.00076 ft/sec



6 ft x 6 ft x 6 ft fiberglass tank


Settling Basins - PerformanceSettling Basins - Performance

0

2

4

6

8

10

0 10 20 30 40 50 60 70 80 90 100

Sol

ids

Rem

oved

(k

g)

.Production Tank Settling Sump Solids Removal (kgs), average daily feed approximately 5 kg.


Settling Basins - PerformanceSettling Basins - Performance

Production TankProduction Tank Settling Sump Cumulative Solids Removal (kgs) Settling Sump Cumulative Solids Removal (kgs)

0

25

50

75

100

125

150

0 10 20 30 40 50 60 70 80 90 100 110

Days

Cum

ulat

ive

Soli

ds R

emov

ed (k

gs)

.

Cum. Solids Removed

Cum. Model Solids Production


Waste Management – Geotextile BagWaste Management – Geotextile BagNorth Caroline State University – Fish Barn – Tilapia/Hybrid Bass North Caroline State University – Fish Barn – Tilapia/Hybrid Bass





Mixed-cell racewaysMixed-cell raceways Design and ConstructionDesign and Construction Water QualityWater Quality Solids ManagementSolids Management

Production Systems OptionsProduction Systems Options


Production Systems - TraysProduction Systems - TraysFour – four tiered trays – PVC / screen material – 4 ft x 8 ft Four – four tiered trays – PVC / screen material – 4 ft x 8 ft


Production Systems - TraysProduction Systems - Trays

Mixed-Cell Mean Velocity Profile Cell #3Mixed-Cell Mean Velocity Profile Cell #3 10 mm Orifices Bottom (corresponding data sets)10 mm Orifices Bottom (corresponding data sets)

0.4

3.2

5.6

8.2

11.1

14.4

16.2

13.1

13.4

12.0

9.0

5.8

1.9

2.6 3.13.9

13.2

11.2

7.6

4.53.5

3.32.4

1.8

0

4

8

12

16

20

Vel

ocit

y (c

m/s

) .

Bottom

Bottom w/Trays

Bottom w/Trays and Airstones


Production Systems - TraysProduction Systems - Trays

Mixed-Cell Mean Velocity Profile Cell #3Mixed-Cell Mean Velocity Profile Cell #3 10 mm Orifices Mid-depth (corresponding data sets)10 mm Orifices Mid-depth (corresponding data sets)

9.5

12.412.6

9.9

7.4

6.0

3.6

1.62.12.01.6

1.3

2.3

3.3

4.5

6.7

2.93.4 3.7 3.2 3.2

4.3

6.3

7.6

0

4

8

12

16

20

Vel

ocit

y (c

m/s

) .

Mid-depth

Mid-depth w/Trays

Mid-depth w/Trays and Airstones


ConclusionsConclusions

• Mixed-cell raceways have significant potential as growout and production systems

• Velocity profiles suggest that systems can be designed with both low and high exchange rates

• Solids management is straight forward and easy

• Construction costs are moderate

• Space utilization is maximized


AcknowledgementsAcknowledgements

Research was supported by the Agriculture Research ServiceResearch was supported by the Agriculture Research Service of the United States Department of Agriculture, of the United States Department of Agriculture,

under Agreement No. 59-1930-1-130under Agreement No. 59-1930-1-130 and Magnolia Shrimp LLC, Atlanta Georgiaand Magnolia Shrimp LLC, Atlanta Georgia

Opinions, conclusions, and recommendations are of the authorsOpinions, conclusions, and recommendations are of the authors and do not necessarily reflect the view of the USDA.and do not necessarily reflect the view of the USDA.

All experimental protocols involving live animals were in complianceAll experimental protocols involving live animals were in compliance with Animal Welfare Act (9CFR) and have been with Animal Welfare Act (9CFR) and have been

approved by the Freshwater Institute Animal Care and Use Committee.approved by the Freshwater Institute Animal Care and Use Committee.


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utilization of a zero-exchange, mixed-cell raceway for marine shrimp production james m. ebeling,...

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