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
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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
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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
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““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
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““New Paradigm”New Paradigm”
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.
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““New Paradigm”New Paradigm”
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
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““New Paradigm”New Paradigm”
Sustainable EngineeringSustainable Engineering
Zero-exchange Production SystemsZero-exchange Production Systems
Mixed-cell racewaysMixed-cell raceways Design and ConstructionDesign and Construction Hydraulic CharacterizationHydraulic Characterization Water QualityWater Quality Solids ManagementSolids Management
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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))
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Nitrogen Treatment PathwaysNitrogen Treatment Pathways
Ammonia ProductionAmmonia Production(metabolism waste products)(metabolism waste products)
Bacterial BiomassBacterial BiomassNitrificationNitrification
REMOVAL MECHANISMSREMOVAL MECHANISMS
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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
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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))
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““New Paradigm”New Paradigm”
Sustainable EngineeringSustainable Engineering
Zero-exchange Production SystemsZero-exchange Production Systems
Mixed-cell racewaysMixed-cell racewaysDesign and ConstructionDesign and Construction Hydraulic CharacterizationHydraulic Characterization Water QualityWater Quality Solids ManagementSolids Management
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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
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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.
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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).
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ConstructionConstruction
Insulation – floors and wallsInsulation – floors and walls
5 cm sand base5 cm sand base
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Tank LinerTank Liner
20 ml HDPE Liner20 ml HDPE Liner
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Drainage SystemDrainage System
Sump TankSump Tank• water levelwater level• harvestingharvesting• solids managementsolids management
Drain lineDrain line
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Pump SystemPump System
0.75 kW Pumps0.75 kW Pumps
Water Distribution ManifoldWater Distribution Manifold
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Downlegs JetsDownlegs Jets
Vertical manifoldsVertical manifolds
OrificesOrifices
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Temperature ControlTemperature Control
Propane HeaterPropane Heater
Heat ExchangerHeat Exchanger
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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
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““New Paradigm”New Paradigm”
Sustainable EngineeringSustainable Engineering
Zero-exchange Production SystemsZero-exchange Production Systems
Mixed-cell racewaysMixed-cell raceways Design and ConstructionDesign and Construction
Hydraulic CharacterizationHydraulic Characterization Water QualityWater Quality Solids ManagementSolids Management
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Hydraulic CharacterizationHydraulic Characterization
SonTek Argonaut AcousticSonTek Argonaut Acoustic Doppler VelocimeterDoppler Velocimeter
3D Probe3D Probe
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Hydraulic CharacterizationHydraulic Characterization
Support StructureSupport Structure
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Hydraulic CharacterizationHydraulic Characterization
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
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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
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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
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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
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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
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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
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Continuing ResearchContinuing Research
Three-dimensional velocity contours of the mixed-cell. Three-dimensional velocity contours of the mixed-cell.
Computer Simulation3-dimensional
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““New Paradigm”New Paradigm”
Sustainable EngineeringSustainable Engineering
Zero-exchange Production SystemsZero-exchange Production Systems
Mixed-cell racewaysMixed-cell raceways Design and ConstructionDesign and Construction
Hydraulic CharacterizationHydraulic Characterization
Water QualityWater Quality Solids ManagementSolids Management
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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
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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
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Water QualityWater Quality
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
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Water QualityWater Quality
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
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““New Paradigm”New Paradigm”
Sustainable EngineeringSustainable Engineering
Zero-exchange Production SystemsZero-exchange Production Systems
Mixed-cell racewaysMixed-cell raceways Design and ConstructionDesign and Construction Water QualityWater Quality Solids ManagementSolids Management
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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
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Settling BasinsSettling Basins
Design to minimize turbulence:Design to minimize turbulence:
vs = 0.0015 ft/sec
Q = Flow 1 gpm
vo = 0.00076 ft/sec
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Settling BasinsSettling Basins
6 ft x 6 ft x 6 ft fiberglass tank
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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
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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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QuestionsQuestions