Development and Challenges Using Recirculation Systems in ...smoltproduksjon.no/Bilder/TidlKonf...

Development and Challenges Development and Challenges Using Recirculation Systems in Using Recirculation Systems in

Chilean Salmon Smolt ProductionChilean Salmon Smolt Production

Gustavo ParadaGustavo Parada

Sunndalsora, Norway Feb 2008Sunndalsora, Norway Feb 2008

The early the betterThe early the better

Opportunities

Visions of the future Challenges

Emergencies

TODAY FUTURE

Time available to device solutions

Cha

nce

of s

ucce

ss

Therefore we mustTherefore we must

Take the Opportunities

Have Visions of the future

Challenges

Emergencies

• Leave part of our time for visualize how the future could be, how thinks can orhave to change disturbing dramatically theway how we do things.

• Define how we can be in that future

• Organize the efforts to develop the futureand generate new answers.

• Plan for the application of the achievementsof your search for answers at the right time.

• Start the application of your efforts, • Be prepared for corrections• Be prepared to see opposition top the new

• Be unprepared for problems thatseem to appear unexpectedly.

And must notAnd must not

A brief background of the salmon farming in ChileA brief background of the salmon farming in Chile

Unfortunately we have not been the champion of looking ahead in technology area.

Therefore, a big number of casesThe challenges become emergencies

Instead of Opportunities

CHILEIs a longCoast Line

FW area

SW area

100 km.

2

1

9

37

6

0

233

43 10

60%of fry

950 km.

1.200 km.

1.200 km.

Fry tank farms some with hatchery

SW farms

20 km.

CHILOÉ: A closer VIEW

AREA OF QUINCHAOIN CHILOÉ

2 km.

Challenges for the production of Challenges for the production of smoltsmolt

High prevalence of diseases with risk of vertical transmission:High prevalence of diseases with risk of vertical transmission:

BKDBKD Bacterial kidney diseaseBacterial kidney diseaseSRSSRS Piscirickettsia salmonisPiscirickettsia salmonis

1987 first cases in 1987 first cases in cohocoho salmonsalmon1995 all sites in X 1995 all sites in X regiregióónn, also in atlantics, also in atlantics

IPNIPN Infectious Pancreatic necrosisInfectious Pancreatic necrosis1997 first cases in few farms1997 first cases in few farms20002000 most most fwfw sites were positive sites were positive

ISAISA Infectious salmon anemiaInfectious salmon anemia2007 declared occurrence in Chile2007 declared occurrence in Chile2008 Marine harvest announces the closing of2008 Marine harvest announces the closing ofall sites in Chiloe.all sites in Chiloe.

A critical process in sanitary managementA critical process in sanitary management

Seawater

Freshwater

High risk of having infected fish transported

to sea sites

Transport stress + Prevalence of diseases =Immune depression Outbreaks in seawater

Horizontal and vertical transmissionLakes positives to IPN

Brood stock with high risk of been positive to IPN, SRS or BKD is transported to

fresh water

SolutionsSolutions

Seawater sites

FreshwaterHatchery

Smoltification

Smolts inmunodepresed recovers their fitness in a clean fallowed sea site

Brood stocks: Completes its cycle in a free of disease close system

Certified free of disease eggs

Smolts in close systems

Healthy and vaccinated fish are transported to empty sites

Brood stocks

Certifiedimported eggs

Qua

rant

ine

sche

me

Some history of the application of recirculation in Some history of the application of recirculation in Chile Chile

1995 2000 2005 2010

Small installation for turbot in Tongoy•Formulation of development project in Fundación Chile

•Small scale RAS designed and built •Bigger scale RAS designed and built • & Creation of INACUI• Success of Smolt produced in RAS

•Camanchaca 1rst industrial application FRY•Marine Harvest FRY Unit

•Marine Harvest Smolt farm

•Application to fish transport

•Marine Harvest pilot RAS

Characteristics of fresh waterCharacteristics of fresh water

Abundant fresh water but

•Temperature to high for incubation 10 – 16°C•Temperature to low for fry and smolt production 5°C

Contains Level seen in source

•High levels of CO2 5 – 20 mg/L•High levels of N2 110 – 130% saturation•Low in O2 3 mg/L•Low hardness <30 mg/L•Low alkalinity <5 mg/L

•High level of Aluminium AL+3 0,5 - 1,2 mg/L•High level of Fe+2 0,5 - 3 mg/L

Recirculation of water reduce the energy requirement

• Cooling water for incubation in 90 - 95%• Heating water for fry and smolt in 60%

Also:• RAS have a built in solution for the high level of CO2• RAS have a built in protection against N2 high level• RAS do not depend on O2 in the make up

• Correcting Alkalinity and Hardness only can be done using RAS,otherwise, the limitation comes from the quantity of chemicals needed.

• Al+3 can be controlled with the addition of 6,8 mg/mg of Sodium silicateNa2SiO3 per 1,0 mg of Al+3, forming innocuous Al2(SiO3)3

• Fe+2 can be adsorbed in a Ionic exchange resin or, • Fe+2 can be oxidized to Fe+3 insoluble, and filtered in a gravitational

sand filter.

The applicability of all of these solutions derivatesfrom the reduction of water use

Development and Challenges Using Recirculation Systems Development and Challenges Using Recirculation Systems in Chilean Salmon Smolt Productionin Chilean Salmon Smolt Production

Improving fish transportImproving fish transport

Environmental conditions in the fish transportEnvironmental conditions in the fish transport

• In Chile, transporting juvenile fish is fact of life.• Fish are transported more than ones in their FW period

• Typical transport by road:

• density of 40-60 kg/m3• O2 injection (mostly without automatic control)• Time of transport could easily vary from 6h to 50h

•Water is change during the trip.(no controlling the water quality and conditions)

• TAN and CO2 accumulates during transportation• NH4+ predominates due to low pH generated by CO2

Environmental conditions in the fish transportEnvironmental conditions in the fish transport

4 tanks of 3000L each5 tanks of 3000L each

1350 kg of fish / (track + trailer)For example:22.500 fish of 60g

200 million smolts needs over 15.000 tripsTanks are fiber glass reinforced plastic, of difficult sanitization

Environmental conditions in the fish transportEnvironmental conditions in the fish transport

Experimental set up

Fish of 43g average, starved2 Tanks at 65 kg/m3 Normal4 Tanks at 120 and 180 kg/m3 RECICLED

Environmental conditions in the fish transportEnvironmental conditions in the fish transport

NH3 + H+ NH4+

----

- -SNH4+

NH4+

NH4+

---- -

S

Na+Na+

Na+Na+

Na+-Na+

Na+Na+

Na+

3 NH4+ + 3 Na++

Regeneration: solution of NaCl and NaOH

Absorption of NH4+ In resin for ionic interchange

Environmental conditions in the fish transportEnvironmental conditions in the fish transport

TAN concentration in each tank

0

5

10

15

20

25

30

0 10 20 30 40 50 60 70Time (hours)

NA

T m

g/L

65A65B120A120B180A180B

Environmental conditions in the fish transportEnvironmental conditions in the fish transport

02468

101214161820

0 20 40 60

horas

mg/k

g/h

Emisión de peces en ayuno, 43g Rate of TAN excretion

hours

Environmental conditions in the fish transportEnvironmental conditions in the fish transport

Carbon Dioxide evolution in each tankC

O2

[mg/

L]

0

10

20

30

40

50

60

70

80

90

100

0 10 20 30 40 50 60 70

CO2 in CO2 out65A 65B120A 120B180A 180B

Time (hours)]

Environmental conditions in the fish transportEnvironmental conditions in the fish transport

Prototype constructed and tested in 2006 / 2007

Full scale prototypeConstructedBut not yet in duty.

Environmental conditions in the fish transportEnvironmental conditions in the fish transport

Idea is:

• Improve the environmental conditions for the transport• Increase productivity of the investment• Reduce variable cost of transport• Reduce risks of transmission of diseases from one

transport to the next

Development and Challenges Using Recirculation Systems Development and Challenges Using Recirculation Systems in Chilean Salmon Smolt Productionin Chilean Salmon Smolt Production

Applying and developing RAS technologyApplying and developing RAS technology

Set up of laboratory scale systemsSet up of laboratory scale systems

Set up of laboratory scale systemsSet up of laboratory scale systems

Set up of laboratory scale systemsSet up of laboratory scale systems

Set up of laboratory scale systemsSet up of laboratory scale systems

Set up of laboratory scale systemsSet up of laboratory scale systems

Set up of laboratory scale systemsSet up of laboratory scale systems

Set up of laboratory scale systemsSet up of laboratory scale systems

0%

20%

40%

60%

80%

100%

120%

140%

160%

180%

0,00 0,50 1,00 1,50 2,00 2,50 3,00

Velocidad Superficial, Vs (cm/s)

Expansi

ón %

Cuarzo -24/+50 Cuarzo -40/+70 Cuarzo -24/+70Arena natural 0,3-0,6mm Arena Natural <40

Set up of laboratory scale systemsSet up of laboratory scale systems

Clean reactor

Start up of fluidized bed biofilterActive reactor

Set up of laboratory scale systemsSet up of laboratory scale systems

Set up of laboratory scale systemsSet up of laboratory scale systems

NH3 and NH4+ (biofilter)

0,0

1,0

2,0

3,0

4,0

5,0

6,0

0 30 60 90 120 150 180 210 240 270 300 330 360 390

DAYS

NH

4 (m

g/L)

0,000

0,005

0,010

0,015

0,020

0,025

0,030

NH

3 (m

g/L)

NH4+

NH3

Set up of laboratory scale systemsSet up of laboratory scale systems

NO2

0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

1

230 235 240 245 250 255 260 265 270

Days

mg/

L

SumpBiofiltro

NO2

0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

1

260 265 270 275 280 285 290 295 300

Days

mg/

L

SumpBiofiltro

Set up of laboratory scale systemsSet up of laboratory scale systems

CO2 Julio

0

5

10

15

20

25

30

35

40

200 205 210 215 220 225 230 235

Días

mg/

L

sump biofiltro stripper LHO

Feed given Wasted Ingested digested excreted Retained [kg] CatabolizedTotal X 0,129X 0,871X 0,601X 0,269X 30,1Protein 0,52X 0,067X 0,453X 0,408X 0,045X 27,2 0,408X-27,2Lipids 0,22X 0,028X 0,192X 0,172X 0,019X 2,9 0,172X-2,9Carbohidrate 0,082X 0,011X 0,071X 0,021X 0,05X 0,021X-0Fibre 0,008X 0,001X 0,007X 0X 0,007XAsh 0,1X 0,013X 0,087X 0X 0,087XWater 0,07X 0,009X 0,061X 0X 0,061X

1,445x(0,408X-27,2) + 2,854x(0,172X-2,9) + 1,185x(0,021X-0) = 46,48Feed utilized [ kg ] 85

EMISIONSUneaten Feed 11,0 kg/day 13%Feaces 17,7 kg/day (dw) 21%

protein 3,8 9%lipids 1,6 9%carbohidrates 4,2 61%fibre 0,6 87%ash 7,4 87%

N-NH3 1,26 kg/dayCO2 51,0 kg/day

BOD 15,9 kg O2 / dayPotential N-NH3 0,79 kg/day

Nutritional model

FEED 52/22 51/21 50/20 52/20* 52/18 48/16 48/12Protein 52,0% 51,0% 50,0% 52,0% 52,0% 48,0% 48,0%Fat 22,0% 21,0% 20,0% 20,0% 18,0% 16,0% 12,0%Carbohidrates 8,2% 10,2% 12,0% 10,0% 12,0% 15,5% 19,4%Fibre 0,8% 1,0% 1,0% 1,0% 1,0% 2,0% 3,0%Ash 10,0% 9,8% 10,0% 10,0% 10,0% 10,0% 9,0%Water 7,0% 7,0% 7,0% 7,0% 7,0% 8,5% 8,6%

AA balance required 89% 88% 88% 86% 83% 83% 76%Feed [kg/day] 58 59 61 60 62 67 73

Uneaten Feed kg/day 12,7 13,0 13,3 13,1 13,6 14,8 16,1Feaces kg/day (dw) 10,8 11,6 12,5 11,8 12,8 15,4 18,1

protein 2,3 2,4 2,4 2,4 2,5 2,5 2,7lipids 1,0 1,0 0,9 0,9 0,9 0,8 0,7carbohidrates 2,6 3,3 4,0 3,3 4,1 5,7 7,8fibre 0,4 0,5 0,5 0,5 0,5 1,1 1,7ash 4,5 4,5 4,7 4,7 4,9 5,3 5,1

N-NH3 kg/day 0,40 0,42 0,44 0,53 0,67 0,67 1,01CO2 kg/day 27,8 28,0 28,2 28,3 28,9 29,2 30,6

BOD kg O2 / day 9,7 10,6 11,4 10,6 11,5 14,0 17,2Potential N-NH3 kg/day 0,48 0,49 0,49 0,50 0,52 0,52 0,57

Results: W=40g; T=14°C; Commercial feed 2002

Set up of laboratory scale systemsSet up of laboratory scale systems

Set up of laboratory scale systemsSet up of laboratory scale systems

Dedicated systems: Feed testing unitDedicated systems: Feed testing unit

Dedicated systems: Feed testing unitDedicated systems: Feed testing unit

Dedicated systems: Feed testing unitDedicated systems: Feed testing unit

Dedicated systems: Feed testing unitDedicated systems: Feed testing unit

Dedicated systems: Feed testing unitDedicated systems: Feed testing unit

Other bio filters: Moving bed bio filter Other bio filters: Moving bed bio filter

Fundación Chile (Quillaipe)

Bigger systems Bigger systems

A plan for building a full scale demonstration unit was achieve in 2004As JV of FCH, private companies, and money for innovation from CORFO.

The plan was to install a big system for:

•Experiment in a big scale•Take experience and visualize opportunities for improvement•Generate an expertise in a selected groupfor engineering new plants, and improve the solutions.

INACUI was created in 2003

Other bio filters: Moving bed bio filter Other bio filters: Moving bed bio filter

INACUIFRESWATER INSTITUTECORNELL UNIVERSITYFUNDACIÓN CHILE

Full scale demonstration plantFull scale demonstration plant

Full scale demonstration plantFull scale demonstration plant

Full scale demonstration plantFull scale demonstration plant

Demonstration Unit Demonstration Unit

Full scale demonstration plant Full scale demonstration plant

(Inacui S.A.)

5 m

Cyclo - BioMarine Biotech

Other medium size unit Other medium size unit

FUNDACIÓN CHILE – UNI-Aqua

Full scale demonstration plant Full scale demonstration plant

A transformation of a existing unit for fry A transformation of a existing unit for fry

A transformation of a existing unit for fry A transformation of a existing unit for fry

A transformation of a existing unit for fry A transformation of a existing unit for fry

RAS Brackish Water RAS Brackish Water SmoltificationSmoltification unit unit

MARINE HARVEST in Chiloé

Chile in the way Chile in the way

In synthesis, We are moving but slow.

Challenges are now concentrated in

•The diseases, Transmission, •The water available is of poor quality•Transportation of fish exposes to disease,•We need to develop a close system for broodstock