The Conservation Fund Freshwater Institute Experiences with a Zero-exchange Mixed-cell Raceway for the Production of Marine Shrimp James M. Ebeling, Ph.D

The Conservation Fund Freshwater InstituteThe Conservation Fund Freshwater Institute

Experiences with a Zero-exchange Experiences with a Zero-exchange

Mixed-cell Raceway for the Production Mixed-cell Raceway for the Production

of Marine Shrimpof Marine Shrimp

James M. Ebeling, Ph.D. James M. Ebeling, Ph.D. Environmental EngineerEnvironmental EngineerThe Conservation FundsThe Conservation Funds

Freshwater InstituteFreshwater Institute

Carla F. WelshCarla F. Welsh Research Associate

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

Cornell UniversityCornell University

Kata L. Rishel Research AssistantResearch Assistant


INTRODUCTIONINTRODUCTION

Application of engineering principles forApplication of engineering principles for

economically sustainable shrimp productioneconomically sustainable shrimp production

Zero-exchange Production SystemsZero-exchange Production Systems

Mixed-cell racewaysMixed-cell raceways


INTRODUCTIONINTRODUCTION

Insatiable Demand for SeafoodInsatiable Demand for Seafood• Increasing market demand Increasing market demand (4 lbs/capita)(4 lbs/capita)

• Changing Market: Changing Market: “white shrimp”“white shrimp”

• 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


““New Paradigm”New Paradigm”

Zero-exchange Systems “Belize System”Zero-exchange Systems “Belize System”

ShrimpShrimp – high health, selectively bred Specific Pathogen Free stock– high health, selectively bred Specific Pathogen Free stock

FeedFeed – low protein feeds in combination with traditional high protein feeds – low protein feeds in combination with traditional high protein feeds

Water managementWater management – zero water exchange, recycling water between crops – zero water exchange, recycling water between crops



Zero-exchange Systems “Belize System”Zero-exchange Systems “Belize System”

Pond designPond design – square shapes, depth of 1.0 to 1.8 m at center, HDPE liner – square shapes, depth of 1.0 to 1.8 m at center, HDPE liner

Pond aerationPond aeration – 30 to 50 hp/ha, completely mixed – 30 to 50 hp/ha, completely mixed

Pond managementPond management – C/N ratio maintained by feed protein and addition of – C/N ratio maintained by feed protein and addition of

additional carbon as needed (molasses, sorghum, sugar, cassava or wheat meal)additional carbon as needed (molasses, sorghum, sugar, cassava or wheat meal)

Sludge managementSludge management – frequent removal from center of pond or by settling – frequent removal from center of pond or by settling

between crops in holding ponds. between crops in holding ponds.



Mixed-cell RacewayMixed-cell Raceway

Water Quality ManagementWater Quality Management – solids and sludge harvesting– solids and sludge harvesting

Indoor SystemsIndoor Systems – environmental control, Biosecurity – environmental control, Biosecurity

Inexpensive modular constructionInexpensive modular construction – HDPE lined raceways – HDPE lined raceways

Harvest EfficiencyHarvest Efficiency – reduced manpower requirements – reduced manpower requirements

““LOCATION – LOCATIONLOCATION – LOCATION”” – near markets, organic, fresh – near markets, organic, fresh



Sustainable EngineeringSustainable Engineering


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


Engineering DesignEngineering Design

• Traditional Ponds – algae based systemsTraditional Ponds – algae based systems

• Recirculation Systems – large fixed film Recirculation Systems – large fixed film

bioreactorsbioreactors

• Zero-exchange systems – heterotrophic bacteriaZero-exchange systems – heterotrophic bacteria

• control WQ with C/N ratiocontrol WQ with C/N ratio• feeds (low protein)feeds (low protein)• carbon sources (sugars, carbohydratescarbon sources (sugars, carbohydrates))


Nitrogen Treatment PathwaysNitrogen Treatment Pathways

Ammonia ProductionAmmonia Production(metabolism waste products)(metabolism waste products)

Bacterial BiomassBacterial BiomassNitrificationNitrification

REMOVAL MECHANISMSREMOVAL MECHANISMS


Nitrification Nitrification (Autotrophic Bacteria)(Autotrophic Bacteria)

Requirements:Requirements: Dissolved OxygenDissolved Oxygen AlkalinityAlkalinity trace mineralstrace minerals fixed film: surface areafixed film: surface area temperature dependenttemperature dependent

Products:Products:

• bacterial biomass (small)bacterial biomass (small)• nitrate-nitrogen (NOnitrate-nitrogen (NO22-N)-N)

• carbon dioxide (COcarbon dioxide (CO22))

• hydrogen ions (pH)hydrogen ions (pH)

TANTAN NO NO22 NO NO33


Heterotrophic Bacterial ConversionHeterotrophic Bacterial Conversion

TANTAN Bacterial Biomass + CO Bacterial Biomass + CO22

Requirements:Requirements:

Nitrogen (ammonia)Nitrogen (ammonia) Carbon (feed, fecal, other sources)Carbon (feed, fecal, other sources) trace mineralstrace minerals temperature dependenttemperature dependent suspended solids suspended solids

Products:Products:

cellular biomass (TSS or TVS)cellular biomass (TSS or TVS) carbon dioxide (COcarbon dioxide (CO

22))





Mixed-cell racewaysMixed-cell racewaysDesign and ConstructionDesign and Construction Hydraulic CharacterizationHydraulic Characterization Water QualityWater Quality Solids ManagementSolids Management


Engineering DesignEngineering Design Mixed-cell RacewayMixed-cell Raceway

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


Engineering DesignEngineering Design

Tank Rotational VelocityTank Rotational Velocity

Controlled by the design of the orifice dischargeControlled by the design of the orifice discharge– Water flow rateWater flow rate

– Discharge velocityDischarge velocity– Number of orificesNumber of orifices

Tank rotational velocity is generally 15 to 20% of the inlet velocity. Tank rotational velocity is generally 15 to 20% of the inlet velocity.


Construction – GreenhouseConstruction – 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).


ConstructionConstruction

Insulation – floors and wallsInsulation – floors and walls

5 cm sand base5 cm sand base


Tank LinerTank Liner

20 ml HDPE Liner20 ml HDPE Liner


Drainage SystemDrainage System

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

Drain lineDrain line


Pump SystemPump System

0.75 kW Pumps0.75 kW Pumps

Water Distribution ManifoldWater Distribution Manifold


Downlegs JetsDownlegs Jets

Vertical manifoldsVertical manifolds

OrificesOrifices


Temperature ControlTemperature Control

Propane HeaterPropane Heater

Heat ExchangerHeat Exchanger


Monitoring and ControlMonitoring and Control

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





Mixed-cell racewaysMixed-cell raceways Design and ConstructionDesign and Construction

Hydraulic CharacterizationHydraulic Characterization Water QualityWater Quality Solids ManagementSolids Management


Hydraulic CharacterizationHydraulic Characterization

SonTek Argonaut AcousticSonTek Argonaut Acoustic Doppler VelocimeterDoppler Velocimeter

3D Probe3D Probe



Support StructureSupport Structure



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 ResultsCell #3 Velocity Profiles at 5 cm off of Bottom

-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

2.5

5 10

15 20

25 30

35 40

1.5 tank exchanges per hour172 m3/s (760 gpm)15 mm discharge orifice1.35 m pressure head15% from center drain

6 kW Pumps (8 Hp)

#2 #3 #1


Research ResultsResearch Results Mixed Cell HydrodynamicsMixed Cell Hydrodynamics

22.3

5.3 5.9

13.7

8.4

0.9

12.010.6

6.4

14.9

20.1

23.5

17.7

9.5

13.7

16.8

19.1

3.5 3.8

11.412.0

15.1

18.217.8

0

4

8

12

16

20

24

Center

0.0-0.5 m

0.5-1.0 m

1.0-1.5 m

1.5-2.0 m

2.0-2.5 m

2.5-3.0

corner

Vel

ocit

y (c

m/s

)

Bottom

Middle

Top


Research ResultsResearch Results

-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

2.5

2 4 6 8 10 12 14 16 18 20 22 24

0.65 tank exchanges per hour58 m3/s (255 gpm)10 mm discharge orifice1.00 m pressure head25% from center drain

1.5 kW Pumps (2 Hp)

#2 #3 #1

Mixed-cell raceway Cell #3


Research ResultsResearch Results Mixed Cell HydrodynamicsMixed Cell Hydrodynamics

Mixed-Cell Mean Velocity Profile Cell #210 mm Orifices 70 cm and 100 cm Head Pressure

2.5

5.0

7.5

9.8

1.8

4.86.4

7.69.0

10.611.5

0.4

10.49.29.7

0.4

0

4

8

12

16

20

Vel

ocit

y (c

m/s

) .

70 cm head pressure

100 cm head pressure


Continuing ResearchContinuing Research

Contour velocity profiles (in m/s) for the 85:15% side-to-center drain ratio Contour velocity profiles (in m/s) for the 85:15% side-to-center drain ratio

Computer Simulation 2-dimensional


Continuing ResearchContinuing Research

Three-dimensional velocity contours of the mixed-cell. Three-dimensional velocity contours of the mixed-cell.

Computer Simulation3-dimensional





Mixed-cell racewaysMixed-cell raceways Design and ConstructionDesign and Construction


Water QualityWater Quality Solids ManagementSolids Management


Water Quality Water Quality

7.0

7.4

7.8

8.2

8.6

9.0

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

pH

Mixed-cell Raceway Production Tank pHMixed-cell Raceway Production Tank pH


Water QualityWater Quality

0.0

0.5

1.0

1.5

2.0

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

TA

N (

mg/

L)

Mixed-cell Raceway Production Tank TANMixed-cell Raceway Production Tank TAN



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


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


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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The Conservation Fund Freshwater Institute Experiences with a Zero-exchange Mixed-cell Raceway for the Production of Marine Shrimp James M. Ebeling, Ph.D