AN INTEGRATED
PHOTO/CHEMOAUTOTROPHIC SYSTEM
SUPPORTING INTENSIVE
SHRIMP AND BIVALVE PRODUCTION
D. E. Brune,
Brune,1 A. G. Eversole,
Eversole,2
K. Kirk1, and A. Aranguren2
1Department
of Agricultural and Biological Engineering
Clemson University, Clemson, South Carolina 29634
2Department
of Aquaculture, Fisheries and Wildlife
Clemson University, Clemson, South Carolina 29634
Partitioned Aquaculture System
Algal nutrient assimilation, limited water discharge,
Higher feed application rates,
Possible algal harvest and utilization
1
Confined PAS Technology for Finfish
Animals confined to
5% of total area
Confinement = ease
of feeding/harvest
15,00015,000-18,000
lb/acre vs. 4,0004,0008,000 lb/acre
4x conventional
catfish production
PAS ADVANTAGES
Reduced Water Use and Discharge; 12% of
Conventional Catfish Culture Water Usage
Production Advantages; Reduced Harvest Labor,
Fish Cohort Management, Predation Elimination
Reduced Aeration Energy Requirements
Nutrient Recovery; Eutrophication Avoidance
Algae and Tilapia as Marketable ByBy-products
2
PAS DISADVANTAGES
Applied to Shrimp Culture
Feed Application Ultimately Limited by
Photosynthetic Rates; 10 -12 gm C fixation/m2
day equal to 350 lb feed/acre day
Shrimp as 22-Dimensional Animal Requiring
System24-7
System-wide 24System-wide Distribution and SystemWater Quality Control
Daily Feed Application Potentially Interrupted by
Cloudy Periods
Shrimp Production Research:
2003 & 2004 Objectives
Design, Develop, Operate PAS for Distributed Animal
Production (Shrimp) with SystemSystem-wide Water Quality
Control in a Zero Discharge System (2003)
Add Suspended Culture Nitrification/Denitrication
Nitrification/Denitrication
Reactor to Avoid CloudyCloudy-Weather Feed Reductions
and to Push System Capacity Beyond Photosynthetic
Limit (2004)
CONFINED ANIMAL
PRODUCTION 5% of Area
Channel Catfish Ictalurus
punctatus
DISTRIBUTED ANIMAL
vs. PRODUCTION 100% of
Area
Pacific White Shrimp
Litopenaeus vannamei
3
Greenhouse Covered Shrimp Culture
Clemson, South Carolina
Simulated Marine Tropical Environment
Greenhouse and
heating system to
extend growing
season
Summer ventilation
Coral Reef™ sea salt
Concrete lined for
research purposes
Not yet economical in
commercial culture
4
SlowSlow-speed, paddlewheel water mixing
Maintain algae in photic zone
Water mixing for homogeneous
environment
Water Circulation
1-3 RPM paddlewheels
5
Four 250 m2 (0.0625 acre) shrimp culture reactors
Oxygen Supply and pH Control
Oxygen and CO2 Tanks
– Emergency O2 BackBack-up
– Early season pH control
(at feed levels below
160 lbs/acre day)
Routine Aeration with
3/4 hp Fountain
Aerators in Flow Path
– (1 to 4 aerators per
unit depending on
loading rate)
6
Algal Culture Control
Nile Tilapia
– Control of Algal Density
(secchi disk)
– Control of Algal Species
(green vs. bluegreen algae)
Internal Water Exchange
(Shrimp to Tilapia Only)
– Intermediate rate (2003)
(average 15% per day)
– Continuous rate (2004)
(average 50% per day)
Solids Removal and Management
(2003 only)
Airlift pumps in sump tubes
Continuous/batch settling for sludge concentration
7
Solids/Shrimp Separation
(2003 only)
Solids concentration with shrimp exclusion tunnel
2004 Addition of Extended Aeration, Suspended
Culture, Nitrification/Denitrification
Nitrification/Denitrification Reactor
(13% of Combined Shrimp Culture Area)
8
Extended Aeration, Nitrification Reactor
(2.5 hours detention time)
Anaerobic Denitrification / Sludge Flotation Zone with
AirliftAirlift-Pump Driven, Sludge Recycle Lines
9
TenTen-Fold Solids Concentration in Reactor Volume
Shrimp Culture System; Summary
Season
Culture Type
Culture Area
Initial Stocking
Litopenaeus vannamei
Aerator Type,
Number, and HP
2003
2004
Algae + Bacteria
Algae + Nitri/Denitr
Reactor
m2
3-250
Shrimp
2
1-250 m Tilapia
3-220 m2 Shrimp
1-250 m2 Tilapia
2-50 m2 Nitri/Denitri
200 shrimp / m2
300 shrimp / m2
1-3, ¾¾-hp Fountain
1212-36 hp/acre
1-4 ¾¾-hp Fountain
1212-48 hp/acre
10
Shrimp Culture System; Summary
Season
2003
2004
Water Salinity
5.2 ppt
12.3 ppt
Waste Removed
50% input N removed
23% input N removed
Maximum Feed
350350-400 lb/acrelb/acre-day
690690-784 lb/acrelb/acre-day
Shrimp Production 12,00012,000-17,700 lb/acre
14,00014,000-31,900 lb/acre
2003 and 2004 Shrimp Feeding
32% Protein
3/32” Pellet
Uniformly dispersed
Feeding based on
water quality critical
levels
– [NH3-N] < 2.52.5-mg/L
– [NO2] < 1.001.00-mg/L
– Algal density
Secchi Depth > 77-cm
– DO > 2.0 mg/L
11
2003 Daily Feed Rate
Significant feed “downtime”
due to cloudycloudy-weather driven water quality constraint
(algae(algae-only system)
2004 Daily Feed Rate
Elimination of “downtime” with Nitri/Denitr reactors & increased
carrying capacity (limited downtime due to aeration limitations)
12
Feed Rates 2004/(2003)
Peak Daily Rates (lb/ac(lb/ac-day) 2004, (2003)
= 784 (350)
Unit 1
Unit 2
= 784 (350)
= 687 (400)
Unit 4
Peak 1414-day Sustainable Rates (lb/ac(lb/ac-day)
Unit 1
= 686 (250)
Unit 2
= 643 (250)
= 660 (225)
Unit 4
Season Average Feed Rates (lb/ac(lb/ac-day)
Unit 1
= 390 (160)
Unit 2
= 385 (155)
Unit 4
= 359 (150)
Shrimp Production 2004/2003
Harvest Densities, % Survival, Net Yield
Unit 1, 2004
– 81% Survival
– 243 Animals/m2
– 31,884 lb/ac
Unit 2, 2004
– 61% Survival
– 184 Animals/m2
– 22390 lb/ac
Unit 4, 2004
– 37% Survival
– 110 Animals/m2
– 14,046 lb/ac
SEASON AVERAGES
2004
– 60% Survival
– 179 Animals/m2
– 22,773 lb/ac
2003
–
–
–
61% Survival
123 Animals/m2
14,686 lb/ac
13
Individual Shrimp Size 2004/2003
Average Weights at Harvest (170 day season)
Unit 1, 2004
16.7 g = 27 ct
Unit 2, 2004
15.3 g = 30 ct
Unit 4, 2004
18.1 g = 25 ct
SEASON AVERAGES
2004
16.7 g = 27 ct
2003
13.6 g = 33 ct
Shrimp Feed Conversion 2004/2003
Unit 1, 2004
FCR = 2.2 : 1
Unit 2, 2004
FCR = 3.1 : 1
Unit 4, 2004
FCR = 4.6 : 1
SEASON AVERAGES
2004
FCR = 3.3/1
2003
FCR = 2.1/1
14
Water Quality Analysis
3 times daily
–
–
–
–
Temperature
DO
pH
AmmoniaAmmonia-N
Daily
– Salinity
– Nitrite
– Secchi depth
Routinely
–
–
–
–
Alkalinity
Net photosynthesis
TOC analysis
Algal biovolumes
Temperature (°C) 2004/2003
Unit 1, 2004
– 23.3 - 32.1
– Average 27.5
Unit 2, 2004
– 22.4 - 32.7
– Average 27.6
Unit 3 (tilapia), 2004
– 23.623.6- 27.9
– Average 27.6
Unit 4, 2004
SEASON AVERAGES
2004
– 23.3 - 32.7
– Average 27.5
2003
– 23.323.3-32.8
– Average 28.1
– 23.7 - 32.3
– Average 27.6
15
Dissolved Oxygen Concentration (mg/L)
2004/2003
Unit 1, 2004
– 1.88 - >20.00
– Average 5.90
Unit 2, 2004
– 0.56 – 19.31
– Average 6.06
SEASON AVERAGES
2004
– 0.560.56-20.0
– Average 6.6
2003
Unit 3 (tilapia), 2004
– 0.270.27-20.0
– Average 6.6
Unit 4, 2004
Low values due to shortshort-term
aerator malfunctions
– 4.53 – 9.13
– Average 6.22
– 1.27 - >20.00
– Average 6.18
Salinity (g/L) 2004/2003
Unit 1, 2004
– 7.30 – 17.50
– Average 12.29
Unit 2. 2004
–
–
6.60 – 17.30
Average 12.25
Unit 3 (tilapia), 2004
– 6.95 – 17.70
– Average 12.01
Unit 4, 2004
SEASON AVERAGES
2004
– 6.66.6-17.7
– Average 12.3
2003
– 0.70.7-8.9
– Average 5.2
– 7.00 – 17.10
– Average 12.27
16
pH 2004/2003
Unit 1, 2004
– 6.33 – 10.32
– Average 7.69
Unit 2, 2004
– 6.91 – 9.59
Average 7.76
Unit 3 (tilapia), 2004
– 7.15 – 8.70
– Average 7.98
Unit 4, 2004
– 7.00 – 9.80
– Average 7.78
SEASON AVERAGES
2004
– 6.36.3-10.32
– Average 7.8
2003
–
–
6.06.0-9.2
Average 7.8
Total Ammonia Nitrogen (mg-N/L)
2004/2003
Unit 1
– 0.4 - 2.7
– Average 1.28
Unit 2
– 0.3 - 2.4
– Average 1.26
Unit 3 (tilapia)
– 0.5 – 1.1
– Average 1.27
Unit 4
– 0.4 - 3.0
– Average 1.31
SEASON AVERAGES
2004
–
–
0.30.3-3.0
Average 1.3
2003
– 0.10.1-4.0
– Average 1.2
17
Nitrite Concentration (mg-N/L)
2004/2003
Unit 1, 2004
– 0.03 – 1.65
– Average 0.47
Unit 2, 2004
– 0.00 – 1.40
– Average 0.4
Unit 3 (tilapia), 2004
– 0.04 - 0.2
– Average 0.15
Unit 4. 2004
SEASON AVERAGES
2004
– 0.00.0-1.7
– Average 0.4
2003
– 0.00.0-0.4
– Average 0.1
– 0.03 - 1.30
– Average 0.41
Secchi Depth (cm) 2004/2003
Unit 1. 2004
– 6 - 23
– Average 13.2
SEASON AVERAGES
2004
– 7 - 23
– Average 13.14
– 5-30
– Average 13.4
Unit 2, 2004
Unit 3 (tilapia), 2004
– 7 - 20
– Average 9.5
Unit 4, 2004
2003
– 5-30
– Average 9.7
– 7 - 28
– Average 14.0
18
Alkalinity (mg-CaCO3/L) 2004/2003
Unit 1, 2004
– 32 - 160
– Average 74.15
Unit 2, 2004
–
–
50 - 168
Average 78.7
Unit 3 (tilapia), 2004
– 30 – 131.1
– Average 87.42
Unit 4, 2004
SEASON AVERAGES
2004
– 3232-242
– Average 85
2003
– 5555-221
– Average 151
– 52 - 242
– Average 99.62
Net Photosynthesis - Unit 1
2004 Change from Photoautotropic (algal) to
Chemoautotrophic dominance as feed level increases
19
Photoautotrophic to:
Chemoautotrophic
With increased feed application
Net Photosynthesis (mg-O2/L/day)
2004/2003
Unit 1, 2004
– 0 – 55.77
– Average 14.60
Unit 2, 2004
– 0 – 62.19
– Average 17.7
Unit 3 (tilapia), 2004
– 0 –43.3
– Average 14.75
SEASON AVERAGES
2004
– 0-62
– Average 15
2003
– 0-76
– Average 17
Unit 4, 2004
– 0 – 56.71
– Average 12.89
20
Algal Density:
Particulate Organic Carbon (mg/L)
Unit 1
– 47.4 – 159.0
– Average 83.8
Unit 2
– 50.8 – 172.1
– Average 80.4
Unit 3 (tilapia)
– 30.9 – 129.7
– Average 73.6
Total
– 10.8 – 172.1
– Average 77.3
Unit 4
– 10.8 – 129.2
– Average 71.5
Carbon Mass Balance 2004
PAS System Carbon Balance
Feed Input
19.0 g-C/m2/day
(0 – 38.0)
CO2 Outgassing / Injection
14.8 g-C/m2/day (net output)
Algal Fixation
5.1 g-C/m2/day
(0 – 10.3)
Shrimp Conversion
0.6 g-C/m2/day
Sludge Removal
3.6 g-C/m2/day
(0.3 – 20.6)
21
Carbon Mass Balance 2003
PAS System Carbon Balance
Feed Input
7.8 g-C/m2/day
(0 – 18.5)
CO2 Outgassing / Injection
4.5 g-C/m2/day (net output)
Algal Fixation
2.7 g-C/m2/day
(0 – 11.5)
Sludge Removal
2.9 g-C/m2/day
(0.3 – 20.6)
Shrimp Conversion
0.4 g-C/m2/day
Nitrogen Mass Balance 2004
PAS System Nitrogen Balance
Nitrification
0.44 g-N/m2/day
Feed Input
2.13 g-N/m2/day
(0 – 4,23)
Algal Fixation
1.0 g-N/m2/day
(0 – 2.06)
Shrimp Conversion
0.16 g-N/m2/day
Denitrification
1.03 g-N/m2/day
Sludge Removal
0.5 g-N/m2/day
22
Nitrogen Mass Balance 2003
PAS System Nitrogen Balance
Nitrification
0.35 g-N/m2/day
Feed Input
0.89 g-N/m2/day
(0 – 2.11)
Algal Fixation
0.48 g-N/m2/day
(0 – 2.04)
Shrimp Conversion
0.10 g-N/m2/day
Sludge Removal
0.44 g-N/m2/day
(0.05 – 3.17)
In 2004, An automated filtration system using Oysters
showed promise as an addition/replacement for tilapia
algalalgal-solids removal and concentration
23
Summary
0.1 HA (0.25 acres) Greenhouse PAS units
– 3 shrimp units exchanging water with single tilapia unit
– Simulated tropical marine environment
Key Components
– Paddlewheel water movers
– Fountain Aerators
– BiologicallyBiologically-driven water column solids control
– Algal water treatment (2003), enhanced with Nitri/Denitri
water treatment (2004)
Conclusions
PAS for successful culture of Pacific White Shrimp
– Nile tilapia (biological control) for internal water exchange
– ZERO external water discharge
– Feed rates exceeding 780 lb/aclb/ac-day
– Maximum shrimp production of 31,884 lb/acre
Limits of system were pushed
– Animals cultured at 179 shrimp/m2
– Nitrogen treatment in excess of algal uptake using extended
aeration, suspended culture, nitrification/denitrification
nitrification/denitrification
– Reduced sludge removal and disposal required
24
Acknowledgements
This research was funded by:
– NOAANOAA-SEAGRANT
– Clemson University, Newman Endowed Chair
Fund
Questions?
David E. Brune
203 McAdams Hall
Clemson University
Clemson, SC 29634-0312
Phone: (864) 656-4068
Fax: (864) 656-0338
Email to: [email protected]
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