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