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    JOURNAL

    OF

    THE

    WORLD AQUACULTURE

    SOCIETY

    Vol.

    25, No.2

    June,

    1994

    An Analysis

    of

    Biological, Economic, and Engineering Factors

    Affecting the Cost of Fish Production in Recirculating

    Aquaculture Systems

    THOMAS

    . U S O R D O

    Department of Zoology and Biological & Agricultural E ngineering,

    North Carolina State University, Raleigh, North Carolina 27695 USA

    PHILIP

    W.

    WESTERMAN

    Department

    of

    Biological & Agricultural E ngineering,

    North Carolina State University, Raleigh, North Carolina 27695 USA

    Abstract

    Aquaculture production in recirculating systems has been the focus of research and development

    efforts for decades. Although considerable resources have been expended on these systems in the

    private sector, there is a scarcity of data on the economic or engineering performance of commercial

    scale recirculating production systems. This paper presents the results of a computer simulation of

    tilapia production in a small recirculating production system. Much of the performance data has

    been developed at a demonstration facility at North Carolina State University. Given the assump-

    tions of the base case simulation, the cost of producing a kilogram of tilapia in the recirculating

    system described is estimated to be 2.79 ( 1.27/lb). The results of a model sensitivity analysis

    indicate that while improvements n the performance efficiency of system components did not greatly

    affect fish production costs, reductions in feed costs and improvements in the feed conversion ratio

    caused the greatest reduction of production cost of all of the operational variables investigated. The

    analysis further indicates that the greatest gains to be realized in improving profitability are those

    associated with increasing the productive capacity or decreasing the investment cost of a recirculating

    fish production system.

    Recirculating aquaculture production

    systems have stirred a great deal of interest

    in the aquaculture community worldwide.

    There is little doubt that most fish grown in

    ponds, floating net pens, or raceways can be

    reared in commercial scale recirculating

    systems, given enough resources. Unfortu-

    nately, the economic viability of growing

    commonly cultured species in recirculating

    systems is not as certain. The question of

    system economics has not always been ad-

    equately addressed prior to the develop-

    ment of an aquaculture business based on

    recirculating technology. Although there are

    numerous corporations and entrepreneurs

    selling “package turnkey” systems, there are

    relatively few reports of profitable com-

    mercial aquaculture recirculating produc-

    tion systems in operation (Losordo et al.

    1989).’ Currently most commercial recir-

    culating production systems in the United

    States are small, less than

    45,000

    kg of pro-

    duction per year, providing fresh high qual-

    ity product at premium prices to niche mar-

    kets. Although there have recently been a

    number of large scale efforts in commercial

    system development, only two large scale

    systems remain operating in the United

    States with long term production of whole-

    sale quantities of fish.

    Given the level of interest and activity in

    commercial recirculating production sys-

    tems, there is a scarcity of data and system-

    Mention

    of

    a specific product or tradename does

    not constitutean endorsement by North Carolina State

    University nor imply its approval to the exclusion of

    other suitable products.

    Copyright by the

    World

    Aquaculture

    Society

    1994

    193

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    194

    LOSORDO AND

    WESTERMAN

    TABLE.

    Simulated change in production cost

    of hy-

    brid striped

    b ss

    in a recirculating system due to a

    10 change

    in

    selected input variables.

    96

    change in

    Changed input variable oroduction cost

    System capacity

    Feed conversion ratio

    Feed cost

    Labor rate of pay

    Mortality rate

    Cost o f electricity

    Cost o f liquid oxygen

    5.0

    4.1

    2.8

    1.8

    1.4

    1.4

    0.5

    After Losordo

    I99 1.

    atic evaluations of the economic aspects of

    these systems in the literature. To reduce

    the number of future economic failures and

    aid in the design and development of suc-

    cessful production systems, non-biased and

    non-proprietary studies of the biological,

    economic and engineering aspects of recir-

    culating systems must be completed.

    As part of a study of the feasibility of

    recirculating aquaculture production sys-

    tems, the authors developed a computer

    model to simulate the biological, engineer-

    ing and economic performance of closed

    systems. The preliminary results were pre-

    sented in Losordo et al. (1989). The findings

    concluded that while it was not economical

    to grow catfish in recirculating systems,

    striped bass hybrids showed promise. A

    sensitivity analysis of the simulation of the

    production cost of hybrid striped bass to

    changes in selected input costs was reported

    in Losordo 199 1). In each simulation, only

    one selected input was adjusted by 10%and

    the resulting fish production cost was re-

    corded. The selected input variables includ-

    ed the cost of bulk oxygen, cost of electricity,

    cost of feed, cost of labor, production mor-

    tality, feed conversion ratio, and system

    carrying capacity. Table

    1

    contains the re-

    sults of the 7 simulations.

    Interestingly enough, a

    1

    OYo intensifica-

    tion of the production capacity of the sys-

    tem (without a corresponding increase in

    the fixed investment) produced the largest

    decline ( 5 ) in production cost. These re-

    sults suggested that future efforts in recir-

    culating production system development

    should be in the intensification of systems

    without making them more expensive.

    This paper will investigate this conclu-

    sion and describe the results of simulations

    of the production of tilapia in a recirculating

    system. The computer model was upgraded

    to more realistically represent a functioning

    recirculating production system and where

    possible, the model utilized verified input

    data from a recirculating fish production

    demonstration system at North Carolina

    State University. The sensitivity of produc-

    tion costs to changes in the variable and

    fixed input costs and the biological and en-

    gineering performance of the system are re-

    ported.

    Computer Simulation Methods

    A general dynamic simulation model of

    recirculating aquaculture systems was de-

    veloped, using a commercially available

    modelling language called STELLAB as a

    framework in which to determine the en-

    gineering, economic and biological perfor-

    mance of recirculating fish production sys-

    tems. While the model will not be described

    in detail in this paper, a description of the

    input and output variables and general

    model structure follows.

    STELLA model overview.

    The computer

    software package referred to as STELLAB

    is a product of High Performance Systems,

    Inc. The computer language was developed

    for use only on the Apple Macintosh com-

    puter. For a description of the programming

    language, the reader is referred to Rich-

    mond et al. 1987).

    The model was originally developed to

    simulate the growth and production of hy-

    brid striped bass or channel catfish. The

    model was expanded for this study to in-

    clude the production of tilapia. Many of the

    engineering simulation functions were also

    expanded and refined for this study. Fish

    growth rate algorithms were selected from

    the literature as listed in Table 2. To run

    the simulation, the user enters the appro-

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    FISH PRODUmON COSTS IN RECIRCULATING SYSTEMS

    195

    TABLE

    .

    Recirculatingfish production system model

    input variables.

    Input variable Selection and/or units

    Species cultured Hybrid Striped Bass

    (Brown

    19898)

    Catfish (Boyd 1978)

    Tilapia (Soderberg

    1990)

    Continuous or Batch

    ode of operation

    Cost of fingerlings each

    Fingerling length mm

    Fingerling weight

    g

    each

    Fish harvest weight kg each

    Fish survival

    System capacity kg

    Nursery decimal fraction

    Growout decimal fraction

    Production cycle length

    Nursery d

    Growout d

    Feed cost

    Fry %/kg

    Juvenile feed %/kg

    Grower feed S

    Finishing feed

    %/kg

    Fry feed

    %

    Juvenile feed %

    Grower feed %

    Finishing feed

    %

    Feed protein content

    Expected feed conversion dimensionless

    Electricity costs

    ratio

  • 8/9/2019 losordo1994

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    196 LOSORDO ND WESTERMAN

    TABLE. Selected recirculatingjishproduction system

    model output variables.

    Output variable Selection and/or un it s-

    Total production cost

    Feed cost

    Labor cost

    Fingerling cost

    Heating costs

    Water recirculating power

    Water costs

    Oxygen cost

    Cost

    of

    borrowed capital

    Cost of operating capital

    Opportunity cost of equi-

    Maintenance cost

    Depreciation cost

    Fish weight g/fish

    System biomass kilograms

    Recirculating flow rate Ipm

    Make-up water flow rate Ipm

    Feed rate kg/d

    /kg of fish produced

    /kg of fish produced

    /kg of fish produced

    /kg of fish produced

    /kg

    of

    fish produced

    /kg of fish produced

    /kg of fish produced

    /kg of fish produced

    /kg of fish produced

    /kg of fish produced

    /kg of fish produced

    /kg of fish produced

    /kg of fish produced

    costs

    ty capital

    and a production cost breakdown for each

    input variable such as feed cost or water cost

    per kg of fish produced. The output vari-

    ables used for the system analysis in this

    report are listed in Table

    3.

    Tilapia Production Simulation

    The recirculating production system sim-

    ulation model was configured to simulate

    the production of tilapia in a small

    43,500

    kglyr

    (96,000

    lbs/yr) production system. The

    following are details of the production sys-

    tem simulated and the simulation model

    assumptions.

    Production system description. The pro-

    duction system was modelled as a contin-

    uous production unit consisting of

    3

    juve-

    nile nursery tanks and 8 growout tanks. Each

    nursery tank was capable of growing up to

    6,560 83

    g tilapia from

    3

    g

    (50.8

    cm,

    2“

    long) animals in

    90

    d. With the harvest of

    one nursery tank each month, the

    3

    nursery

    tanks provide enough 83 g tilapia to restock

    2

    growout tanks per month. Each growout

    tank provides for the production of ap-

    proximately 3,200 567 g (1.25 lb) tilapia in

    approximately 120d. With

    8

    growout tanks,

    2

    harvests per month can be scheduled to

    TABLE

    .

    Growout system compon ent cost and depre-

    ciation estimates.

    Compo-

    Cost nent

    installed life

    System component

    0 )

    (Yr)

    Fiberglass production tank

    Floating bead filter

    Rotating biological contactor

    Aeration or oxygen delivery sys-

    Pipes and valves

    Pumps (3 each

    @

    120)

    Solenoid valves

    &

    timers

    Heater and controller

    Feed delivery system

    tem

    Total cost

    3,800

    4 000

    4,000

    1,500

    400

    360

    1,000

    240

    1,000

    16,300

    15

    10

    1 . 5

    15

    10

    3

    5

    5

    5

    yield an overall yearly tilapia production of

    slightly over

    43,500

    kg

    (96,000

    lb).

    Systems design and cost. The cost esti-

    mates in this section are derived from the

    development of a demonstration “Fish

    Barn” and recirculating production systems

    at North Carolina State University. The

    components described here are, for the most

    part, of the same scale and similar to those

    currently in use at the North Carolina Fish

    Barn project.

    The simulated production system is

    housed within a

    28

    m x 11 m

    (92’

    x

    36’)

    metal clad, wooden post and beam barn with

    minimal insulation and an earthen floor.

    Each tank is configured with an individual

    water renovation system consisting of an in-

    line resistance type electric water heater, a

    0.57

    m3

    (20

    ft3) floating bead filter as de-

    scribed by Losordo (199 1) and a V4 hp ro-

    tating biological contactor (total surface area

    =

    418

    m2) used in series (Fig. 1). Dissolved

    oxygen additions to the culture tanks were

    provided by either in tank diffised aeration

    or whole recycle stream oxygenation with

    pure oxygen (depending on the simulation

    input selections). Each growout system con-

    sists of a

    4.25

    m diameter,

    1.45

    m deep

    fiberglass tank. Total cost of each growout

    tank system with all associated support

    equipment installed was modelled to be

    16,300. The individual component costs

    and estimated useful life are listed in Table

    4.

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    FISH

    PRODUCTION COSTS IN RECIRCULATING SYSTEMS

    197

    Rotating Biological Contactor

    2

    (surface area

    =

    418 m )

    d

    4.24m

    Culhut Tank

    23.375

    liters

    Foam

    Fractionator

    FIGURE

    Typical simulated growout system component layout.

    The nursery tank systems were modelled

    as 3 m diameter, 1.25

    m

    deep fiberglass

    tanks. Water and wastewater treatment for

    all three nursery tanks are provided for by

    one bead filter and one RBC as described

    above. Total cost of the nursery production

    system is $18,490 (Table

    5 ) .

    A

    depreciation rate for each system was

    estimated by the “straight line” method as-

    suming a salvage value of zero dollars at the

    end of the useful component life. The au-

    thors chose to assign a salvage value of zero

    for each asset due to the specialized (in many

    cases custom fabrication) nature and the

    limited market for used recirculation sys-

    tem components. The yearly rate of depre-

    ciation was estimated by calculating the dol-

    lar value per year of depreciation for each

    component (cost installedlcomponent life),

    then summing the yearly depreciated value

    for each component and dividing by the to-

    tal system cost (Yearly Depreciation Rate

    = ((L: (cost installed/component life))/total

    system cost)).

    Building cost, including water and elec-

    trical service installation, was valued at

    $129.10 per square meter ($12/f t2) or

    $39,744. The total production system

    equipment cost was valued at an additional

    $148,890 or approximately $3.42 of fixed

    investment per kg of annual production ca-

    pacity ($1.55/lb). The total investment cost

    for the fish production system including the

    TABLE

    . Nursery system component cost and depre-

    ciation estimates.

    Com-

    Cost ponent

    System installed life

    component

    ( 1

    (Yr)

    Fiberglass tanks

    (3

    @ 2,000)

    Floating bead filter

    Rotating biological contactor

    Aeration or oxygen delivery sys-

    Pipes and valves

    Pumps (3 each @ 120)

    Solenoid valves

    &

    timers

    Heater and controls

    Feed delivery system

    tem

    Total cost

    6,000

    4,000

    4,000

    1,500

    400

    360

    1,000

    230

    1,000

    18,490

    15

    10

    7.5

    15

    5

    3

    5

    5

    5

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    FISH

    PRODUCTION COSTS IN RECIRCULATING SYSTEMS

    199

    1 m

    FIGURE

    . Simulated recirculatingfrsh production system layout,

    8

    growout tanks and 3 nursery tanks.

    lation indicate that under the given condi-

    tions, overall fish production cost will be

    approximately $2.79/kg ($1.27/lb). Given

    the same set of assumptions, except with

    pure oxygen as the oxygen source, the cost

    of production was estimated to be $2.86/kg

    ($1.30/lb). Subsequent modelling runs de-

    termined that the cost of bulk oxygen would

    need todecrease to $0.18/m3 ($0.51/100 ft3)

    for the overall fish production cost to equal

    that of the simulation of a system with at-

    mospheric aeration. The cost of bulk liquid

    oxygen in the United States ranges from ap-

    proximately $0.09-$0.28/m3 ($0.25- 0.801

    100 ft3)depending on the distance from the

    source of liquid oxygen and quantity used.

    The production costs simulated in the base

    case analysis for the system as described are

    generally too high to be economically com-

    petitive in the wholesale fish fillet market.

    Currently, only the local markets for live or

    whole fresh tilapia on ice product would

    support such production costs. However,

    there are production and engineering im-

    provements that could be made to improve

    the economic viability ofthese systems. The

    sensitivity analysis of the modelled system

    that follows provides a means for estimating

    the impact of changes within the system.

    The results of the sensitivity analysis can be

    used to assist in identifying areas in need of

    further research and development where

    improvements to recirculating systems can

    have their greatest performance and eco-

    nomic impacts.

    System Sensitivity Analysis

    total of 12 model input variables were

    selected for study in the sensitivity analysis

    of the simulated system. The 12 variables

    are grouped and reported as biological vari-

    ables, variable operating cost inputs, engi-

    neering performance variables, and system

    or fixed cost variables. Twelve modelling

    “runs” were executed each time only one

    of the variables was changed by 10%. In

    most cases the variables were changed to

    provide a simulated improvement in the

    system performance. Some simulated vari-

    able values, such as fish survival, used in

    the base case simulation were so good (based

    on North Carolina Fish Barn performance

    experience) that a 10% change for the better

    was judged as not being realistic. In these

    cases the variables were changed for the

    worse. In all cases, changes in fish produc-

    tion costs were monitored. The overall re-

    sults of the sensitivityanalysis can

    be

    viewed

    in Table 7.

    Biological variables. The model input

    variables that directly affect the biological

    performance of the cultured product are feed

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    200 LOSORDO AND WESTERMAN

    (

    Production Cost = 2.79 /

    kg

    ( 1.27 / lb)

    FIGURE

    .

    Simulated base case production cost

    of

    tilapia in a recirculating system.

    conversion ratio (FCR) and fish mortality

    rate. When the FCR was reduced from 1.3

    to

    1.17

    (a

    10%

    change) the overall cost of

    producing tilapia changed by O.OSS/kg

    ($0.04/lb), a

    3.2%

    change. Analysis of the

    production cost breakdown yielded inter-

    esting results. In initiating he modelling run,

    the user specifies the harvest size and total

    weight of fish at harvest. When a lower FCR

    is specified, the model simulates a more ef-

    ficient conversion of feed to fish flesh and

    calculates that less feed is used to produce

    the same mass of fish. While one could ex-

    pect the cost of feed per

    kg

    of fish to be less,

    the simulation results also indicated that

    changes in new water use, heating require-

    ments, recirculation rate, aeration rate and

    electric demand charges also occurred. While

    the changes in water recirculation rate, new

    water addition rate and aeration rate were

    a direct result of less feed being added to

    the system in the simulation (e.g., a lower

    TAN production rate, lower nitrate nitrogen

    production rate, lower oxygen consumption

    rate), the change in heating requirement was

    caused by the reduced water exchange rate.

    The electric demand charge decreased as a

    result

    of

    decreased water pumping and heat-

    ing rates.

    The mortality rate of fish is considered a

    biological variable and was increased for the

    sensitivity analysis by 10%. The 1

    Ooh

    change

    in mortality rate yielded only a

    2.3%

    change,

    or a O.O66/kg($0.03/lb) difference in over-

    all production cost. The detailed simulation

    results showed that although some changes

    occurred in almost all production cost cat-

    egories, the major changes occurred in feed

    cost and fingerling cost per kgof production.

    The reader should note that mortality was

    simulated as a fractional constant loss over

    the entire growth cycle. Losses later in the

    growth cycle would have a greater effect on

    production costs than losses occumng ear-

    lier in the cycle. This type of mortality could

    be simulated as a timed pulsed input van-

    able change during a simulation run.

    Operating cost variables. The modelled

    operating cost input variables that were

    changed (decreased

    10%)

    in this sensitivity

    analysis were the cost of feed, electricity,

    liquid oxygen, and labor. As in the previous

    study (Losordo

    1991),

    the greatest change

    in the cost of fish production among these

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    20 1

    FISH PRODUCTION COSTS IN RECIRCULATING SYSTEMS

    input variables was caused by a change in

    feed cost (2.1%). This may not be totally

    unexpected as feed costs are the largest sin-

    gle production cost in the base case simu-

    lation (Fig.

    3).

    The sensitivity analysis in-

    dicates that changes in the electricity rate,

    labor rate of pay, and oxygen cost rate caused

    changes in production costs of

    1.5%, 1.4%

    and 0.1% respectively.

    These results, in concert with the FCR

    sensitivity results, suggest that significant

    production cost savings could be realized if

    a feed that produced a better FCR were

    available at a reduced cost. Feed manufac-

    turers market improved feed conversion ra-

    tios as a reason to pay more for specialized

    feeds. The sensitivity analysis results

    sug-

    gest that production cost savings from a

    1OYo

    reduction in the FCR will in fact outweigh

    the increase in production costs due to a

    10%

    increase in feed cost. In reality, im-

    provements in the overall physical and bi-

    ological performance of recirculating sys-

    tems are realized when using higher quality

    feeds. The model, as configured, could not

    account for these changes.

    It is also interesting to note that while

    recirculating systems have been assumed to

    be energy intensive, a 10% change in the

    electric cost rate effected only a 1.5% change

    in the total production cost of fish.

    Engineering performance variables. The

    modelled engineering performance vari-

    ables that were investigated in this study

    were recirculating pump efficiency, biolog-

    ical filter efficiency, oxygen injection system

    transfer efficiency, and aeration system ox-

    ygen transfer efficiency. Surprisingly,

    10%

    changes in these variables produced no more

    than a

    0.5%

    change in total production cost.

    It may be hard to justify expending a great

    deal of research and development time im-

    proving the performance efficiency of each

    of these components given these results. The

    reader should not misunderstand this state-

    ment, however. The authors are suggesting

    only that biological filters that “remove”

    100% of the ammonia nitrogen per pass, or

    pumps that run at 80% efficiency, may not

    TABLE Results

    of

    he simulation sensitivity analysis:

    The change in production cost due to a

    10

    change

    in

    selected input variables.

    % change in

    Changed input variable production cost

    System capacity

    System cost

    Feed conver sion ratio

    Mortality rate

    Feed cost

    Cost o f electricity

    Labor

    rate

    of

    pay

    Aeration efficiency

    Pump efficiency

    Cost of liquid oxygen

    Filter efficiency

    Oxygen transfer efficiency

    4.1

    3.5

    3.2

    2 .3

    2.

    1.5

    1.4

    0.5

    0 . 2

    0.1

    0.1

    0.1

    be the key to economic viability. On the

    other hand, a great deal of development ef-

    forts are needed in improving the reliability

    of biological filters. Indeed, the unexpected

    failure of a biological filter or undetected

    failure of an oxygen injection system can do

    major damage in a short period of time to

    the economic viability of a commercial fish

    production system.

    System andjixed cost variables. The re-

    sults of this sensitivity analysis support the

    findings described in Losordo 1 99 1).

    Changes in either the system capacity or

    overall system cost had greater impacts on

    the total production cost than changes in

    any other variable. A 10% increase in sys-

    tem capacity was simulated without an as-

    sociated change in investment. That is to

    say that the physical production system was

    not altered although the stocking rate (car-

    rying capacity) was increased by

    10%.

    This

    change caused a

    4.19’0

    decrease in the total

    production cost. The reduction in the cost

    of production due to an increase in carrying

    capacity was essentially due to more pro-

    duction for the same fixed investment. To

    increase capacity, the model simulated pro-

    portionally higher rates of use for feed, elec-

    tricity, pumping, aeration and operating

    capital. The savings come in the form of

    more production for the same loan, equity

    and labor costs.

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    202 LOSORDO

    AND WESTERMAN

    Similarly,

    a

    10°h reduction in the overall

    investment for the same production capac-

    ity yielded a 3.5% change in production cost.

    Insight into this finding may be gained by

    reviewing the results from the base case pro-

    duction analysis in Fig. 3. Over 4 l0h of the

    costs associated with the production of the

    fish are directly related to the initial in-

    vestment cost of the system. In changing

    the cost of the system, the calculated costs

    of maintenance, depreciation, interest pay-

    ments and cost of equity are all directly af-

    fected.

    Discussion

    The simulated production results out-

    lined above point out areas in production

    technology where improvements can im-

    pact the financial viability of recirculating

    production systems. The reader should note

    that the changes in the model input vari-

    ables were accomplished without concur-

    rent changes in the costs associated with

    making these changes within the system. In

    most cases improvements in any variable

    will have an associated cost incurred in

    making the change. For example, feeds that

    provide a higher FCR will most likely cost

    more. Similarly pumps that are more effi-

    cient will also cost more.

    The results of this study point to one area

    that may provide substantial production cost

    savings. The authors believe that these cost

    savings can result from reducing the overall

    cost of recirculating production systems

    while maintaining component reliability and

    longevity. These results can be viewed from

    another perspective. While component de-

    sign criteria are considered by performance

    only, the results of the performance effi-

    ciency sensitivity analysis suggest that this

    alone is not of primary importance. The

    results of this study suggest that perhaps

    component performance should be com-

    bined with the cost of ownership of these

    components (which ultimately make up the

    total cost of the system) into a “perfor-

    mance/cost” factor. For example, a biolog-

    ical filter could be evaluated according

    to the total grams of ammonia nitrogen re-

    moved per day per cost ofannual ownership

    ((g

    TAN/yr) ($/yr)

    = g

    TAN/$). The costs

    associated with ownership on an annual ba-

    sis would include annual interest and equity

    cost for the purchase of the component

    combined with depreciation and mainte-

    nance costs. Given a basic reliability factor,

    one should seek to maximize the calculated

    value of this variable. For example, the ro-

    tating biological filter at the North Carolina

    Fish Barn had an average TAN removal

    capacity of 129 g/d during a study described

    by Westerman et al. (1 993). Given an actual

    purchase price of $3,000, and assuming a

    component life of

    7.5

    yr, a maintenance cost

    rate

    of 5 ,

    an interest rate of 13%, equity

    interest rate of 9.5 , and a debt to equity

    ratio of

    1

    , the performance/cost factor can

    be estimated to be 53

    g

    TAN/$. The floating

    bead filter utilized at the North Carolina

    Fish Barn removed an average of

    46 g

    TAN/d over the same test period. With an

    actual purchase price of $3,200, an assumed

    component life of 10 yr and similar eco-

    nomic cost rate assumptions, the perfor-

    mance cost factor would be calculated to be

    20

    g

    TAN/$. Additionally a fluidized bed

    sand filter was evaluated over the same pe-

    riod during the study (Westerman et al.

    1993). The monitoring results indicated that

    an average of 37

    g

    TAN/d was oxidized to

    nitrite. Given the actual purchase price of

    $1,000, a 10 yr life and similar economic

    cost rate assumptions, the performance/cost

    factor was calculated to be

    5 1 g

    TAN/$. If

    it is assumed that these components have

    similar performance reliabilities, then the

    fluidized bed filter or the RBC filter would

    be a better value based upon this evaluation

    criterion. However, the reader should not

    lose sight of the fact that the floating bead

    filter performed a suspended solids removal

    function as well as nitrification. To “nor-

    malize” the results of this analysis, perhaps

    the performance/cost factor must account

    for all functions to be performed by the fil-

    tration system.

    While the ultimate criteria for evaluating

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    11/11

    FISH PRODUmION COSTS N RECIRCULATINGSYSTEMS

    203

    the cost of producing fish in a system is the

    cost per unit weight of production, evalu-

    ation criteria as outlined above may provide

    designers with economic measures to com-

    pare individual components and compo-

    nent performance. Engineering perfor-

    mance and economic performance must be

    balanced to provide an optimum produc-

    tion system for the specific site, species, and

    operating personnel requirements.

    Conclusions

    The challenges for recirculating systems

    designers and engineers are many. Recir-

    culating systems and system components

    must be designed to be manufactured at a

    lower cost or to utilize components that are

    currently available to other industries at

    lower prices. Where possible the carrying

    capacity of a system must be increased with-

    out increasing cost or sacrificing system re-

    liability.

    The following specific conclusions may be

    reached as a result of the data presented in

    this study:

    1) Given the assumptions of the base case

    simulation, the cost of producing a kilogram

    of tilapia in the small recirculating system

    described is estimated to be

    $2.79

    ( 1.271

    lb).

    2) Changes in the engineering perfor-

    mance efficiency of the system components

    did not greatly change the total production

    cost.

    3) Changes in the feed cost had the great-

    est impact on production cost of all of the

    operational variables investigated.

    4) Improvements in the feed conversion

    ratio can have a significant impact on pro-

    duction costs. However, these savings could

    be offset by associated increases in feed

    prices.

    5)

    The greatest gains to be realized in im-

    proving profitability are those associated

    with increased production capacity or de-

    creased system investment cost.

    Acknowledgments

    The research and demonstration program

    in recirculating aquaculture technology at

    North Carolina State University is sup-

    ported by the Agricultural Research Service

    and the Cooperative Extension Service of

    the College

    of

    Agriculture and Life Sciences

    of North Carolina State University and the

    Energy Division of the North Carolina De-

    partment of Commerce.

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    Losordo,

    T. M. 1991. Engineering considerations in

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