Professional Documents
Culture Documents
Water System
Design
James M. Ebeling, M.B. Timmons, Ph.D.
Ph.D. Biological & Environmental Engineering
Research Engineer
Cornell University
Aquaculture Systems Technologies, LLC
Ithaca, NY
New Orleans, LA
1
Overview of System Design
Carbon Dioxide Aeration
Removal Air/Oxygen
Monitoring &
System Control Disinfection
Fish Culture Tank
Biosecurity
Program Sludge Sludge
In a real world system, the individual unit processes are usually linked together as
the water flows through each process (circulation). Usually 5-10% of the discharge
from the culture tank is removed from the center drain and because of a ‘tea cup’
effect has a high solids loading. Some form of settable solids removal device (swirl
separator, settling basin, etc) pretreats this flow stream, which is then combined
with the remaining 90-95% of the discharge from a side outlet. The remaining
suspended solids are then removed usually by a rotating microscreen filter. The
water then flows to some form of biofiltration, such as a trickling tower, bead filter,
fluidized sand filter, moving-bed bioreactor etc, where the ammonia is converted to
nitrate by bacteria. At high loading densities, a carbon dioxide stripping column is
then used to remove excess CO2 and aerate the water to saturation. Finally an
oxygenation device is employed to supersaturate the flow to provide sufficient
oxygen for the high levels of stocking used in commercial systems. In some cases,
a UV or Ozone system is added to disinfect the returning water stream as part of a
biosecurity program.
2
Design Requirements
For any design, some assumptions need to me made, hopefully based either on actual experience
or reputable research.
3
Design Assumptions
For any design, some
assumptions need to be made,
hopefully based either on
actual experience or reputable
research.
For any design, some assumptions need to me made, hopefully based either on actual experience
or reputable research.
4
Design Assumptions
Assuming: 454,000 kg/yr production (1 million pounds/year)
For any design, some assumptions need to me made, hopefully based either on actual experience
or reputable research.
5
System Biomass Estimation
Biomasssystem =
(annual production ) ⋅ ( FCR)
rfeed
454,000 kg fish / yr ⋅1.3 kg feed / kg fish 1 yr
= ⋅
(0.012 kg feed / day ) / kg fish 365 day
= 129,600 kg fish in system / day
Based on the design goals, the total biomass in the production system can be estimated from the
Feed Conversion Rate (FCR) and the feed rate (rfeed).
6
Total Oxygen Requirements
• Estimate the oxygen demand of system’s feeding fish:
• where:
• RDO = average DO consumption Rate
= kg DO consumed by fish per day)
• aDO = average DO consumption proportionality constant
= kg DO consumed per 1 kg feed
Ranges from 0.4 to 1.0 kg O2/kg feed – cold water to warm water
To estimate the oxygen demand of the system, the average dissolved oxygen consumed per kg
of feed is used (aDO) and multiplied by the feed rate (rfeed) and the total biomass of the system
(biomasssystem).
7
Total Flow Requirement – Oxygen Load
• Estimate water flow (Q) required for fish’s O2 demand:
• Assuming oxygen:
• DOinlet = 18 mg/L
• DOeffluent= 4 mg/L (@ steady state)
1
QTotal = rDO ⋅
(DO inlet − DOeffluent )
1166 kg O2 106 mg L 1
= ⋅ ⋅ ⋅
day kg (18 − 4) mg 1440 min/ day
= 57.84 m 3 / min (15,280 gal / min)
Recirculating Aquaculture Systems Short Course
If only aeration was employed, the change in DO across the culture tank would be only 4 mg/L,
where the inlet would be at 90 to 95% saturation (8 mg/L) and the tank might be as low as 4
mg/L (Tilapia). A more aggressive, but usually achievable, inlet DO would be 20-22 mg/L,
which would produce an available DO across the culture tank of about 14 mg/L, with the tank
DO raised to 6 mg/L. In practice, this is about the maximum DO loading that can be safely
managed.
8
Total Tank Volume Requirements
Assume an average fish density across all culture tanks in
the system:
• culture density = 80 kg fish/m3
A culture density of 80 kg/m3 is considered the average density found within the entire system.
The maximum density in a culture tank might be 120 kg/m3 while other tanks in the same
facility might be as low as 40 kg/m3. In reality, unless batch production is used in the entire
facility, the average culture density found in facility will be considerably less than the maximum
density that could be supported in a given culture tank. Also, because densities can vary
between tanks, some tanks would receive more water than others to supply the extra oxygen
needed to support these fish.
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Check Culture Tank Exchange Rate
EXCH TANK = VolumeTotal / QTotal
min
= 1,620 m 3 ⋅
57.84 m 3
= 28 min
Rule of Thumb
In general, a culture tank exchange every 30-60 minutes provides good flushing of waste
metabolites while maintaining hydraulics within circular culture tanks (when the tank inlet and
outlet structures are designed properly.
10
Number of Tanks Required
If future expansion of the farm is expected to achieve 2-4 times more production, then maybe
choose 50 ft diameter tanks. Otherwise, choosing 30 ft tanks would be a okay choice to achieve
1 million lb maximum production.
To use tanks as large as 50 ft diameter requires knowledge of tank inlet and outlet structure
designs to ensure that good mixing is achieved and that safe rotational velocities can be
maintained for fish health and for flushing settleable solids. If water must rotate about the axis
of a culture tank once in 60-90 seconds to achieve good solids flushing, then the fish swimming
in larger (e.g., 50 ft tanks) must be capable of swimming at these speeds. Water velocities are
greatest near the tank’s outside wall where the perimeter distance is πD. Therefore, in a 50 ft
tank fish swimming with the current near the tank’s outside wall would be swimming between
1.7-2.6 ft/s. Maximum safe swimming velocities for salmonids are considered to be between 1-
2 body length per second. However, in ‘Cornell-type’ dual-drain tanks the water velocity
decreases as the fish swim closer to the center of the tank, which allows fish to select what
velocity they want to swim against by moving to different locations in the culture tank.
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Tanks Design Summary
Ten Production Tanks • Flow Rate (30 min exchange)
5,000 Lpm (1,320gpm)
• Diameter
9.14 m ( 30 ft ) • Biomass Density
86 kg/m3 (0.72 lbs/gal)
• Water depth
2.3 m (7.5 ft)
• Culture volume per tank
150 m3 (40,000 gal)
• Oxygen Demand
117 kg O2/day (257 lbs/day)
This is just one of many system designs that could be chosen based on the tank design, system
yearly production and stocking density. Fewer larger tanks could be used, more smaller tanks.
Any system design has to be based on decisions that best fit the management style, resources,
site limitations and market demand for the product.
Based on a system using 10 tanks at 150 m3 volume, the flow rate through each tank can be
estimated from the exchange rate of 30 min and the volume as 5,000 Lpm or 1,320 gpm. Actual
biomass density is slightly higher at 86 kg/m3, but still reasonable for an oxygen enriched
system. The oxygen consumed in the tank increases slightly, but if the tank DO is reduced to 5
mg/L then the influent Oxygen concentration would have to be about 21 mg/L, easily reached
with a LHO or Speece cone.
12
Solids Capture
• Dual-drain System
• Settling Basin
• Swirl Separator
• Microscreen Filter
• Propeller Washed Bead Filter
13
Solids Capture
One Options for Solids Capture:
One commonly used system for solids capture is to use a Dual-drain system, where
approximately 10 to 15% of the water is removed from the center drain and has a
high solids loading due to the swirl separation effect of a circular tank. This high
suspended solids flow is first treated with a simple swirl separator to remove the
large, easily removed fecal matter and uneaten feed. This flow stream is then
combined with the side-wall discharges and is polished with a high-flow rate
microscreen filter with a 60 to 100 micon mesh filter screen.
14
Biofiltration/Nitrification
It is helpful in any discussion of biofilter principals and advantages and disadvantages of the various
choices to have a basic set of definitions and terminology. Generally, the following terms are used in
the design and characterization of biofilters:
Void space is the volume not occupied by biofilter media, and void ratio is that volume divided by
the total volume of the biofilter. High void ratios reduce clogging by having large open spaces that
allow solids to pass easily through the filter.
Cross-sectional area refers to the area of the filter bed looking in the direction of the water flow.
Filter top area is usually one of the last parameters selected in the filter design, to yield a desired
hydraulic loading rate.
Hydraulic loading rate is the volume of water pumped through the biofilter per unit of cross-
sectional area of the filter per unit of time. Typically expressed as gpm/ft2 or m3/m2 day. There is
usually both a minimum and a maximum hydraulic loading rate for biofilters.
Specific surface area is the surface area of the media per unit volume. The higher the specific
surface area of a media, the more bacteria can grow on a unit volume, and the greater the total
ammonia removal per unit volume of filter. The media size, void ratio and specific surface area are
all interrelated. The smaller the size, the larger the specific surface ratio and the smaller the void
ratio.
15
Biofilter Design – Step 1
Based on the oxygen demand of the feed, the percent body weight feed per day, the
stocking density and the volume of the tank, the daily oxygen demand can be
determined. This should reflect the final production carrying capacity of the
system, plus a little extra in case you can’t sell the fish when you expected too.
In this case, a MBB and a Trickling Tower are to be used as biofilters for
nitrification. Since both of these filters provide the oxygen required for
nitrification, only the demand by the fish and any heterotrophic bacteria are used.
This is an very difficult number to come by and is usually estimated from other
similar systems and research.
16
Biofilter Design – Step 2
Step 2: Calculate water flow requirement (Qtank) required for fish DO demand.
Assume: DOinlet = 18 mg/L (pure oxygen aeration system)
DOtank = 4 mg/L (warm water 24 Deg. C, Tilapia!!)
1
QTANK = rDO ⋅
(DOinlet − DOeffluent )
117 kg O2 106 mg L 1
= ⋅ ⋅ ⋅
day kg (18 − 4) mg 1440 min/ day
= 5,800 L / min (1,530 gal / min)
The water flow is a simple mass balance assuming that all the oxygen is provided
by the incoming water to the production tank.
17
Biofilter Design – Step 2 (cont)
This is just a quick check to determine the tank exchange rate. For fingerling and
sensitive species, the exchange rate should be from 2 to 4 times per hour. For
finally growout and hardy species, 1 to 2 exchanges per hour may be adequate.
18
Biofilter Design – Step 3
Step 3: Calculate TAN production by fish (PTAN)
(Note: Feed is 35% protein)
PTAN = F * PC * 0.092 = F * 0.35 *0.092 = 0.032
where: PTAN = Production rate of total ammonia nitrogen, (kg/day)
F = Feed rate (kg/day)
PC = protein concentration in feed (decimal value)
Determine the amount of ammonia produced by the fish based on total feed fed.
19
Ammonia Assimilation Rates
Trickling or RBC
Surface area of media 0.2 to 1.0 g/m2 day 1.0 to 2.0 g/m2 day
(100 – 300 m2/m3)
Granular
(bead/sand) Volume of media 0.6 to 0.7 kg/m3 day 1.0 to 1.5 kg/m3 day
(> 500 m2/m3)
Ammonia assimilation rates for biofilters based on Volumetric and Areal TAN
conversion rates.
20
Biofilter Design – Step 4 (MBB)
Step 4: Calculate volume of media, Vmedia based on the Volumetric
nitrification rate (VTR)
PTAN
V media =
VTR
5 . 0 kg TAN
= = 8 . 23 m 3
kg TAN
0 . 605
m3
21
Biofilter Design – Step 4 (MBB)
Step 4: Calculate volume of biofilter, Vbiofiler based on a fill ratio of 65%.
V media
V biofilter =
Fill %
8 . 23 m 3
= = 12 . 66 m 3
0 . 65
This would require a tank (3200 gal) with dimensions of 7 ft diameter, 11 ft tall.
Note that no safety factor was considered in this design!!!!
It can be assumed that from 10 to 30% of the TAN will be removed by in-situ
nitrification (on tank wall, pipe wall, suspended culture).
22
Biofilter Design – Step 4 (Trickling Tower)
Step 4: Calculate the surface area (Amedia) required to remove PTAN from
the Areal TAN removal rate (ATR) (0.45 g TAN/m2 day)
PTAN
A media =
ATR
kg TAN 1, 000 g
5 .0 ⋅
day kg
= = 11,100 m 2
0 . 45 g TAN
m 2 day
10 . 76 ft 2
11,100 m 2 ⋅ = 120,000 ft 2
m2
Recirculating Aquaculture Systems Short Course
Calculate the surface area (Amedia) required to remove PTAN from the Areal TAN
removal rate (ATR). Based on experience with the submerged trickling tower, the
estimated Areal TAN removal rate is 0.45 g TAN/m2 day.
23
Biofilter Design – Step 5 (Trickling Tower)
Step 5: Calculate volume of media based on the specific surface area
(SSA), example BioBlock = 200 m2/m3 (61 ft2/ft3)
Amedia
Vmedia =
SSA
11,100 m 2
= 2
= 55.5m 3
m
200 3
m
24
Biofilter Design – Step 6 (Trickling Tower)
Step 6: Calculate the biofilter cross-sectional area from required flow for
the fish oxygen demand (Qtank) and the hydraulic loading rate, HLR of
250 m3/m2 day (4.4 gpm/ft2).
Qtank
Abed =
HLR
L 1m 3 1 1,440 min
= 5800 ⋅ ⋅ ⋅
min 1,000 L 250m 3 day
2
m
= 33.4 m = 360 ft
2 2
Calculate the biofilter cross-sectional area from required flow for the fish oxygen
demand (Qtank) and the hydraulic loading rate, HLR. The hydraulic loading rate is
dependent on the type of filter and media used and for this trickling tower a value of
250 m3/m2 was assumed.
25
Biofilter Design – Step 7 (Trickling Tower)
From high school math class: area = π (Dia)2 / 4
diameter = [ 4 * area / π]1/2
The diameter of a two trickling towers, Dbiofilter, with this cross sectional area is:
4 ⋅ Abed 4 ⋅16.7 m 2
Dbiofilter = = = 4.61m = 15 ft
π 3.14
Finally use that math you learned in High School. Its often wiser to use three filters
rather than one large one.
26
Biofilter Design – Step 8 (Trickling Tower)
Step 8: Calculate the biofilter depth (Depthmedia) from
the biofilter cross-sectional area (Amedia) and volume (Vmedia).
Vmedia 16.7m 3
Depthmedia = = 2
= 3.62m = 11.9 ft
Amedia 4.61m
Finally use that math you learned in High School. Its often wiser to use three filters
rather than one large one.
27
Aeration / Oxygenation Options
yMulti-staged low head oxygenators (LHO)
yPacked or spray columns
yPressurized columns
yEnclosed mechanical surface mixers
Finally use that math you learned in High School. Its often wiser to use three filters
rather than one large one.
28
Tank Oxygen Requirements
• Estimate the oxygen demand of system:
• where:
• RDO = average DO consumption Rate
• = kg DO consumed by fish per day)
• aDO = average DO consumption proportionality constant
• = kg DO consumed per 1 kg feed
• Ranges from 0.4 to 1.0 kg O2/kg feed – cold water to warm water
To estimate the oxygen demand of the system, the average dissolved oxygen consumed per kg
of feed is used (aDO) and multiplied by the feed rate (rfeed) and the total biomass of the system
(biomasssystem).
29
Tank Oxygen - Speece Cones
(Design Requirement: 117 kg O2 / day or 4.88 kg / hr)
To estimate the oxygen demand of the system, the average dissolved oxygen consumed per kg
of feed is used (aDO) and multiplied by the feed rate (rfeed) and the total biomass of the system
(biomasssystem).
30
CO2 PRODUCTION
• Molar basis
• 1 mole of CO2 is produced for every
1 mole O2 consumed
• Mass basis
• 1.38 g of CO2 is produced for every
1 g O2 consumed
Production – on a molar basis 1 mole of carbon dioxide is produced for every mole
of oxygen consumed by fish. Converting to a mass basis this results in 1.38 grams
of carbon dioxide being produced for every 1 gram of oxygen consumed by fish.
What’s important here is that carbon dioxide is produced by the fish at a greater rate
than oxygen is consumed.
31
CO2 Control Options
The carbon dioxide control options considered in the computer model include packed tower
stripping, addition of sodium hydroxide, dilution through water exchange, in-tank and side-stream
surface aeration, and in-tank and side-stream diffused aeration.
32
Stripping Column Design
• Design criteria used for the forced-ventilation
cascade column:
• hydraulic fall of about 1.0-1.5 m
• hydraulic loading of 1.0-1.4 m3/min per m2
5,000 L min⋅ m 2 m3
plan area =⋅ ⋅ ⋅
min 1.4 m 3 1,000 L
= 3.6 m 2 = 38.4 ft 2
33
Stripping Column Design
• Design criteria used for the forced-ventilation
cascade column:
• volumetric G:L of 5:1 to 10:1
34
Ozone Requirements
• Estimate the ozone requirement of system’s
feeding fish:
• where:
• aozone = kg ozone added per 100 kg feed
35
Putting It All Together
Carbon Dioxide Aeration
Removal Air/Oxygen
Disinfection
Fish Culture Tank
Remember this is only one small part of the overall design. Now you need to
determine all the other component sizes.
36