The Conservation Fund Freshwater Institute Experiences with a Zero-exchange Mixed-cell Raceway for the Production of Marine Shrimp James M. Ebeling, Ph.D. Environmental Engineer The Conservation Funds Freshwater Institute Freshwater Institute Carla F. Welsh Research Associate Michael B. Timmons, Ph.D. Professor Cornell University Kata L. Rishel Research Assistant

The Conservation Fund Freshwater InstituteINTRODUCTION Application of engineering principles for economically sustainable shrimp production  Zero-exchange Production Systems  Mixed-cell raceways

The Conservation Fund Freshwater InstituteINTRODUCTION Insatiable Demand for Seafood Increasing market demand (4 lbs/capita)Increasing market demand (4 lbs/capita) Changing Market: “white shrimp”Changing Market: “white shrimp” Increase Supply – “global market” placeIncrease Supply – “global market” place Decreasing PriceDecreasing Price Sophistication of ConsumerSophistication of Consumer “organic”“organic” sustainable production methods sustainable production methods local produce local produce

The Conservation Fund Freshwater Institute “New Paradigm” Zero-exchange Systems “Belize System”  Shrimp – high health, selectively bred Specific Pathogen Free stock  Feed – low protein feeds in combination with traditional high protein feeds  Water management – zero water exchange, recycling water between crops

The Conservation Fund Freshwater Institute “New Paradigm” Zero-exchange Systems “Belize System”  Pond design – square shapes, depth of 1.0 to 1.8 m at center, HDPE liner  Pond aeration – 30 to 50 hp/ha, completely mixed  Pond management – C/N ratio maintained by feed protein and addition of additional carbon as needed (molasses, sorghum, sugar, cassava or wheat meal)  Sludge management – frequent removal from center of pond or by settling between crops in holding ponds.

The Conservation Fund Freshwater Institute “New Paradigm” Mixed-cell Raceway  Water Quality Management – solids and sludge harvesting  Indoor Systems – environmental control, Biosecurity  Inexpensive modular construction – HDPE lined raceways  Harvest Efficiency – reduced manpower requirements  “ LOCATION – LOCATION ” – near markets, organic, fresh

The Conservation Fund Freshwater Institute “New Paradigm” Sustainable Engineering  Zero-exchange Production Systems  Mixed-cell raceways  Design and Construction  Hydraulic Characterization  Water Quality  Solids Management

The Conservation Fund Freshwater Institute Engineering Design Traditional Ponds – algae based systemsTraditional Ponds – algae based systems Recirculation Systems – large fixed film bioreactorsRecirculation Systems – large fixed film bioreactors 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, carbohydrates )carbon sources (sugars, carbohydrates )

The Conservation Fund Freshwater Institute Nitrogen Treatment Pathways Ammonia Production (metabolism waste products) Bacterial Biomass Nitrification REMOVAL MECHANISMS

The Conservation Fund Freshwater Institute Nitrification (Autotrophic Bacteria) Requirements:  Dissolved Oxygen  Alkalinity  trace minerals  fixed film: surface area  temperature dependent Products: bacterial biomass (small) bacterial biomass (small) nitrate-nitrogen (NO 2 -N) nitrate-nitrogen (NO 2 -N) carbon dioxide (CO 2 ) carbon dioxide (CO 2 ) hydrogen ions (pH) hydrogen ions (pH) TAN  NO 2  NO 3

The Conservation Fund Freshwater Institute Heterotrophic Bacterial Conversion TAN  Bacterial Biomass + CO 2 Requirements:  Nitrogen (ammonia)  Carbon (feed, fecal, other sources)  trace minerals  temperature dependent  suspended solids Products:  cellular biomass (TSS or TVS)  carbon dioxide (CO 2 )

The Conservation Fund Freshwater Institute “New Paradigm” Sustainable Engineering  Zero-exchange Production Systems  Mixed-cell raceways  Design and Construction  Hydraulic Characterization  Water Quality  Solids Management

The Conservation Fund Freshwater Institute Engineering Design Mixed-cell Raceway Pum p 4” Manifold Pipe SR TANK Sludge Disposal Sump & Settling w/ Stirring Pump Harvest by screen capture 6” drain line

The Conservation Fund Freshwater Institute Engineering Design Tank Rotational Velocity Controlled by the design of the orifice discharge – Water flow rate – Discharge velocity – Number of orifices Tank rotational velocity is generally 15 to 20% of the inlet velocity.

The Conservation Fund Freshwater Institute Construction – Greenhouse 16.3 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).

The Conservation Fund Freshwater InstituteConstruction Insulation – floors and walls 5 cm sand base

The Conservation Fund Freshwater Institute Tank Liner 20 ml HDPE Liner

The Conservation Fund Freshwater Institute Drainage System Sump Tank water level water level harvesting harvesting solids management solids management Drain line

The Conservation Fund Freshwater Institute Pump System 0.75 kW Pumps Water Distribution Manifold

The Conservation Fund Freshwater Institute Downlegs Jets Vertical manifolds Orifices

The Conservation Fund Freshwater Institute Temperature Control Propane Heater Heat Exchanger

The Conservation Fund Freshwater Institute Monitoring and Control Monitoring Water Level Water Level Air Pressure Air Pressure Manifold Pressure Manifold Pressure Heating Loop Pressure Heating Loop Pressure Water Temperature Water Temperature Air Temperature Air Temperature Sound Level Sound Level Power Power

The Conservation Fund Freshwater Institute “New Paradigm” Sustainable Engineering  Zero-exchange Production Systems  Mixed-cell raceways  Design and Construction  Hydraulic Characterization  Water Quality  Solids Management

The Conservation Fund Freshwater Institute Hydraulic Characterization SonTek Argonaut Acoustic Doppler Velocimeter Doppler Velocimeter 3D Probe

The Conservation Fund Freshwater Institute Hydraulic Characterization Support Structure

The Conservation Fund Freshwater Institute Hydraulic Characterization Grid Layout for one cell 0.5 m grid lines one sample/sec 20 sec average

The Conservation Fund Freshwater Institute Research Results 1.5 tank exchanges per hour 172 m 3 /s (760 gpm) 15 mm discharge orifice 1.35 m pressure head 15% from center drain 6 kW Pumps (8 Hp) #2 #3 #1

The Conservation Fund Freshwater Institute Research Results  Mixed Cell Hydrodynamics

The Conservation Fund Freshwater Institute Research Results 0.65 tank exchanges per hour 58 m 3 /s (255 gpm) 10 mm discharge orifice 1.00 m pressure head 25% from center drain 1.5 kW Pumps (2 Hp) #2 #3 #1 Mixed-cell raceway Cell #3

The Conservation Fund Freshwater Institute Research Results  Mixed Cell Hydrodynamics

The Conservation Fund Freshwater Institute Continuing Research Contour velocity profiles (in m/s) for the 85:15% side-to-center drain ratio Computer Simulation 2-dimensional

The Conservation Fund Freshwater Institute Continuing Research Three-dimensional velocity contours of the mixed-cell. Computer Simulation 3-dimensional

The Conservation Fund Freshwater Institute “New Paradigm” Sustainable Engineering  Zero-exchange Production Systems  Mixed-cell raceways  Design and Construction  Hydraulic Characterization  Water Quality  Solids Management

The Conservation Fund Freshwater Institute Water Quality Mixed-cell Raceway Production Tank pH

The Conservation Fund Freshwater Institute Water Quality Mixed-cell Raceway Production Tank TAN

The Conservation Fund Freshwater Institute Water Quality Mixed-cell Raceway Production Tank NO 2 -N

The Conservation Fund Freshwater Institute Water Quality Mixed-cell Raceway Production Tank TSS

The Conservation Fund Freshwater Institute “New Paradigm” Sustainable Engineering  Zero-exchange Production Systems  Mixed-cell raceways  Design and Construction  Water Quality  Solids Management

The Conservation Fund Freshwater Institute Settling Basins Sedimentation: Advantages Simplest technologies Little energy input Relatively inexpensive to install and operate No specialized operational skills Easily incorporated into new or existing facilities Sedimentation: Disadvantages  Low hydraulic loading rates  Poor removal of small suspended solids  Large floor space requirements  Resuspension of solids and leeching

The Conservation Fund Freshwater Institute Settling Basins Design to minimize turbulence: v s = ft/sec Q = Flow 1 gpm v o = ft/sec

The Conservation Fund Freshwater Institute Settling Basins 6 ft x 6 ft x 6 ft fiberglass tank

The Conservation Fund Freshwater InstituteConclusions 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

The Conservation Fund Freshwater InstituteAcknowledgements Research was supported by the Agriculture Research Service Research was supported by the Agriculture Research Service of the United States Department of Agriculture, of the United States Department of Agriculture, under Agreement No under Agreement No and Magnolia Shrimp LLC, Atlanta Georgia and Magnolia Shrimp LLC, Atlanta Georgia Opinions, 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 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.

The Conservation Fund Freshwater Institute Questions