Post on 25-Apr-2020
St Andrews Science Seminar October 12, 2012
Salmon Farming in Land-Based Closed-
Containment Systems
Steven Summerfelt
St Andrews Science Seminar October 12, 2012
Land and Water
Conservation
Community and
Economic Development
Training and Education
St Andrews Science Seminar October 12, 2012
Global Fish Harvest & Farmed Production
• Fish provide between 40-60% of the world's protein
• Harvest of fish species that provide fish meal & oil has remained static, i.e., 20-25 million mton/yr – Many capture fisheries are over-exploited
• Human population and income growth has created a shortage of food fish
• Aquaculture must grow to meet this demand
St Andrews Science Seminar October 12, 2012
Most Seafood Comes From Aquaculture
Salmon Shrimp Trout Catfish Tilapia
85% of U.S. Seafood is Imported
St Andrews Science Seminar October 12, 2012
United States Farm Production
• Fish production (approximate) – CATFISH 210 million kg/yr – TROUT 16 million kg/yr – SALMON 18 million kg/yr – TILAPIA 9 million kg/yr
• Terrestrial Animals – POULTRY 17 billion kg/yr (#1 in World) – CATTLE 10.6 billion kg/yr (#1 in World) – HOGS 10.0 billion kg/yr (#2 in World) – TOTAL 37.6 billion kg/yr
0.5% of terrestrial animal production
St Andrews Science Seminar October 12, 2012
United States Farm Production
• Terrestrial animal production is highly regulated & controlled – No point source discharge allowed – Physical barriers help prevent pathogen spread – Control of what the animal eats
St Andrews Science Seminar October 12, 2012
United States Catfish Production
• Pond systems are relatively environmentally friendly – Solar/algae powered treatment within ponds – Point source discharge is heavily regulated
St Andrews Science Seminar October 12, 2012
Salmon Net Pen Production
• Like a CAFO, but – no discharge limits – no capacity to capture wastes – Inadequate physical barriers to prevent
pathogens from spreading into or out of farm
St Andrews Science Seminar October 12, 2012
Fish Farming: Major Environmental Challenges
• Resource constraints: – Limited water supplies – Limited marine fish meal/oil supplies – Water pollution & impacts on watersheds
• Separation of farmed fish from wild fish: – Transmission of pathogens into & out of the farm – Domesticated stocks escaping & interacting with wild
populations
St Andrews Science Seminar October 12, 2012
• How do we achieve new efficiencies in feeding a growing global population with increasing environmental impact conflicts and looming resource constraints?
Fish Farming: Major Environmental Challenges
St Andrews Science Seminar October 12, 2012
Production Technologies must protect the environment and the wholesomeness of the fish, while providing for economic opportunity
Containment is Necessary for Sustainable Aquaculture
St Andrews Science Seminar October 12, 2012
Water Consumption
• Globally, agriculture consumes around 70% of available water – more than 80% of available water in the
developing world.
• Land-based closed-containment systems for fish farming do not consume water, but return it to the environment after its use – Small water requirements are less impacted by
climate change
St Andrews Science Seminar October 12, 2012
Containment is Necessary for Sustainable Aquaculture
• Insufficient water resources for flow-through fish culture systems.
• Closed-containment system can increase production on a limited water supply by 5 to 100+ fold
St Andrews Science Seminar October 12, 2012
Value of Water Rights in Western United States
• Blue Lakes Trout Farms sold their water rights for $30 million – About 2 million lb/yr trout production in Snake
River Canyon, Idaho
• Clear Springs Trout Farm might ask $300 million to sell water rights – About 20 million lb/yr trout production in Snake
River Canyon, Idaho
St Andrews Science Seminar October 12, 2012
Containment is Necessary for Sustainable Aquaculture
• Land-based closed-containment systems are essentially giant water treatment facilities
• Recirculating water is the engine powering the system
• Water use is typically < 1% of flow-through culture practices
St Andrews Science Seminar October 12, 2012
Containment is Necessary for Sustainable Aquaculture
• Land-based, closed-containment systems: – Enhance separation of farmed and wild
• Prevent escapees, disease, & interaction between wild & farmed fish
– Optimize site selection • Move farms away from sensitive environments and closer
to markets • Locate farm where electric & land are cheap
– US$ 0.02-0.06 / KWH
St Andrews Science Seminar October 12, 2012
Containment is Necessary for Sustainable Aquaculture
• Land-based, closed-containment systems – Exclude pathogens – Minimize use of pesticides, antibiotics, &
chemo-therapeutics • For 10 years & 200 ton production, we have not used
– vaccines – pesticide – antibiotic – chemotherapeutic (other than salt)
St Andrews Science Seminar October 12, 2012 18
Containment is Necessary for Sustainable Aquaculture
• RAS have a relatively small point source discharge – Must meet discharge permit limits
• Place wastes into relatively small & concentrated effluent flows. – Increase waste treatment efficiency,
> 90-99% waste capture is possible; – Improved waste capture will reduce TMDL
discharged, • Total Maximum Daily Load;
– Reduce the size and cost of effluent treatment,
St Andrews Science Seminar October 12, 2012
Containment is Necessary for Sustainable Aquaculture
• Reclaim nutrients – Agronomic application of biosolids to crops – Aquaponics (ultimate in local production)
Recent article: “Fertilizer is a better buy than gold”!
St Andrews Science Seminar October 12, 2012
Fish Production in a Controlled Environment
• Control water quality, photoperiod, fish feed, density, & swimming speed
St Andrews Science Seminar October 12, 2012
Commercial-Scale Closed-Containment Systems
• Adopt new innovative technologies – Commercial-scale is an agri-business – Most competitive economics of production
Bell Aquaculture’s New 1000 ton/yr
Addition
St Andrews Science Seminar October 12, 2012
Taking Advantage of Large & Deep Circular Culture Tanks
• Large and deep tanks are much more efficient in fixed & variable costs!
(Courtesy of Josh Goldman)
St Andrews Science Seminar October 12, 2012
Culture Tank Hydraulics
Optimize water rotation & mixing
Dual-drains improve management of rotation and provide for solids separation at tank and
optimized swimming speed for fish.
St Andrews Science Seminar October 12, 2012
Fish Harvest Technologies
• Sidewall harvest box – Clam-shell grader used to
crowd fish so they slide into dewatering area
St Andrews Science Seminar October 12, 2012
Solids Removal • Integrate dual-drain culture tanks, settlers, and drum filters
St Andrews Science Seminar October 12, 2012
Large-Scale Biofilters
• Fluidized-Sand Biofilters achieve high TAN removal efficiency and maintain low NO2-N
St Andrews Science Seminar October 12, 2012
CO2 & O2 Control
• Forced-ventilated cascade column – Strip 50-60% of CO2 each pass
• Low head oxygenation – Create O2 ≥ 200% sat.
• Return flow to culture tank – Control CO2 ≤ 20 mg/L – Maintain O2 of 100% sat.
LHO
Cascade Aeration Column
St Andrews Science Seminar October 12, 2012 28
Examples of Existing Closed-Containment Fish Farms
• Atlantic salmon smolt (MANY worldwide) – Marine Harvest’s Sayward South Hatchery (BC)
(designed by PRAqua Techn.)
St Andrews Science Seminar October 12, 2012
Farms Now Producing Salmon in Land-Based Systems
• Aquaseed – Sweetspring Salmon, Rochester, Washington (Coho salmon)
• Teton Fisheries LLC – Miller Hutterite Colony, Choteau, Montana (Coho salmon)
• Hill Fisheries LLC – East End Hutterite Colony, Havre, Montana (Coho salmon)
• Yantai Salmon Farm – Shandong Oriental Ocean Sci-Tech Co., Yantai, Shandong Province, China (Atlantic salmon)
• BDV SAS, Normandie, France (Atlantic salmon)
St Andrews Science Seminar October 12, 2012
Examples of Existing Closed-Containment Fish Farms
Courtesy of Per Heggelund
St Andrews Science Seminar October 12, 2012
Examples of Existing Closed-Containment Fish Farms
• Teton Fisheries LLC and Hill Fisheries LLC
St Andrews Science Seminar October 12, 2012
Shandong Oriental Ocean Sci-Tech Co. (slide courtesy of Idar Schei, AquaOptima)
Yantai Salmon Farm (Yantai, Shandong Province, China)
St Andrews Science Seminar October 12, 2012
BDV SAS (Normandie, France)
(Photo courtesy of Jonas Langeteig)
St Andrews Science Seminar October 12, 2012
Potential Projects
• North America potential projects for salmon growout in land-based closed containment systems: – British Columbia 6 projects (2 in const; 5 planned)
– U.S. 6 projects (3 built; 3 planned) • Europe
– Denmark 2 project (1 in const; 1 planned) – Scotland 1 project (planned)
• China (2 built, several planned) • Chile (2 planned)
St Andrews Science Seminar October 12, 2012
Farms Preparing To Producing Salmon in Land-Based Systems
• Langsand Laks, Hvide Sande, Denmark (Atlantic salmon); construction ending this fall – Deborah Haust, Atlantic Sapphire
• Namgis First Nation – K’udas, Port McNeill, British Columbia, Canada (Atlantic salmon); construction ending this fall – Eric Hobson, The SOS Marine Conservation Foundation
• Sustainable Blue, Centre Burlington, Nova Scotia, Canada (Atlantic salmon); converting to salmon with a 375-500 tonne farm planned – Dr. Jeremy Lee, Sustainable Blue
St Andrews Science Seminar October 12, 2012
Langsand Laks, Hvide Sande, Denmark
• 1000 tonne/yr Atlantic salmon (16 m x 6 m deep culture tanks) – Atlantic Sapphire
Photos courtesy Thue Holm
St Andrews Science Seminar October 12, 2012
Namgis First Nation’s Land-Based Salmon Farm, Port McNeill, BC
• 300-500 tonne/yr initial module to expand to 2000-3000 tonne/yr
• Construction to finish this fall
St Andrews Science Seminar October 12, 2012
Sustainable Blue’s Land-Based Atlantic Salmon Facility
Project Location: Centre Burlington, NS
St Andrews Science Seminar October 12, 2012
Farms Preparing To Producing Salmon in Land-Based Systems
• There are more than a half dozen farms in the design, permitting or financing stage (as reported by the press) – Atlantic Sapphire, mid-Atlantic USA (Atlantic salmon) – Palom Aquaculture, Gouldsboro, ME, USA (Atlantic
salmon) – NeoSalmon, Los Lagos Region, Chile (Atlantic salmon) – Danish Salmon AS, Hirtshals, Denmark (Atlantic
salmon)
St Andrews Science Seminar October 12, 2012
Yellow Perch Bell Aquaculture, Albany, IN
Examples of Existing Closed-Containment Fish Farms
St Andrews Science Seminar October 12, 2012
Bell Aquaculture, Albany, IN Vertically integrated
Examples of Existing Closed-Containment Fish Farms
St Andrews Science Seminar October 12, 2012 42
Examples of Existing Closed-Containment Fish Farms
• Barramundi – Australis Aquaculture, Turners Falls, MA
Courtesy Josh Goldman
St Andrews Science Seminar October 12, 2012 43
Examples of Existing Closed-Containment Fish Farms
• Tilapia – Blue Ridge Aquaculture, Martinsville, VA
(photos courtesy of http://www.blueridgeaquaculture.com/tilapia.cfm)
St Andrews Science Seminar October 12, 2012 44
Examples of Existing Closed-Containment Fish Farms
• Sturgeon – Northern Divine (Target Marine, BC) – Other farms in NC, FL, CA
St Andrews Science Seminar October 12, 2012
Virginia Cobia Farms
Examples of Existing Closed-Containment Fish Farms
St Andrews Science Seminar October 12, 2012
Atlantic Salmon Growout Trials in Freshwater Closed-Containment Systems at the
Conservation Fund Freshwater Institute
Steven Summerfelt, Thomas Waldrop, John Davidson Christopher Good, P. Brett Kenney, Bendik Fyhn Terjesen,
William Wolters
St Andrews Science Seminar October 12, 2012
Acknowledgments
• Support for The Conservation Fund Freshwater Institute: – U.S. Department of Agriculture,
Agricultural Research Service • 1st salmon studies finished in 2011 • Gaspe and St John River strain
– Atlantic Salmon Federation • 2rd Growout Trial finished in 2012 • St John River strain salmon were harvested
at 24-26 months post-hatch – Moore Foundation
• 3th Growout Trial • Cascade strain salmon now 20 months post-
hatch
St Andrews Science Seminar October 12, 2012
Atlantic Salmon Federation Funded Growout Trial
• Atlantic Salmon, Saint John River strain (Cooke)
• Jan 2010 - Eyed eggs arrive • March 2010 - First Feeding • May 1, 2011 Stocked into growout at 340 g • Feb 27, 2012 – First harvest at 4 kg/fish
St Andrews Science Seminar October 12, 2012
Process Flow Drawing of Closed-Containment System
fluidized-sand
biofilter
10 HP reuse
pumps
pump sump
radial flow
settler
150 m3 dual-drain culture
tank drum filter
make-up water
frequent discharge of backwash
flow
supernatant
intermittent (24 times/day) discharge of solids from base
of cone
backwash water
CO2 stripping unit stacked over a LHO & sump tank
60% flow 40% flow
system overflow
15% bottom drain flow
4700 L/min strip
LHO
St Andrews Science Seminar October 12, 2012
Closed-Containment System
• 150 m3 Culture Tank Volume – 4900 L/min recirc flow – 30 min HRT
• 260 m3 System Volume – 12 to 140 L/min make up
water flowrate – 15 to 1.3 day HRT – 99.8 to 97.2% flow reuse
High flushing rate to keep water ≤ 16.5˚C in summer
St Andrews Science Seminar October 12, 2012
Water Temperature Control
• Makeup water flow adjusted to maintain water temperature at 14.5-16.5˚C
St Andrews Science Seminar October 12, 2012
Grow-Out Trial Results: Water Quality
• Mean Water Quality in Culture Tank – Temperature 15.5˚C – Dissolved Oxygen 10.8 mg/L – Dissolved Carbon Dioxide 9.2 mg/L – Total Ammonia Nitrogen 0.11 mg/L – Nitrite Nitrogen 0.01 mg/L – Nitrate Nitrogen 20 mg/L – Total Suspended Solids 1.3 mg/L – Total Phosphorus 0.87 mg/L
St Andrews Science Seminar October 12, 2012
Atlantic Salmon Growth
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ASF Trial Salmon
Net pens growth data in Maine (Wolters, 2010)
St Andrews Science Seminar October 12, 2012
Late September 2011-Remove Males Harvested Males
• 2 kg, Sept 30, 2011 • 3.5 kg, Jan 20, 2012
St Andrews Science Seminar October 12, 2012
Primary Harvests
• Harvested Premium Salmon from Feb 20 to May 2, 2012 – 4 kg mean size – ~7 tonne produced =
15,000 pound
St Andrews Science Seminar October 12, 2012
Mortality, Jumpers, and Culls
• Mortality 3.9% • Culls 5.6% • Jumpers 1.9% • Total 11.4%
St Andrews Science Seminar October 12, 2012
Salmon Biomass Density
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vertical arrows indicate harvest events
St Andrews Science Seminar October 12, 2012
• Feed Conversion of 1.09 feed : 1.0 gain • Commercial diet with 40:30 protein: fat • 1.7 condition factor (net pen industry is ~1.3) @ final harvest
ASF Grow-Out Trial Results St John River Strain
St Andrews Science Seminar October 12, 2012
Escapees
• No fish observed in the effluent fish exclusion area.
St Andrews Science Seminar October 12, 2012
Grow-Out Trial Results St John River Strain
• No kudoa (parasite that liquefies the fillet) • No sea lice • No obligate pathogens detected in screening
– No ISA virus – No Pancreatic Disease
• No losses to seals/sharks • No escapes to wild salmon rivers
St Andrews Science Seminar October 12, 2012
Chemotherapeutics Used in Salmon Growout Trial
• No vaccination (saves $$ & stress) • No antibiotics or pesticides used at any time • No formalin used at any time • Small amount of hydrogen peroxide used in
the sac fry and early parr stage for fungus. • Total salt used to treat fungus: 14,400 lbs.
St Andrews Science Seminar October 12, 2012
Product Quality Results
• MUST DEPURATE salmon for 10 days after removing harvested fish from recycle system – Depurate in partial reuse system with little biofilm – Purges off-flavors, i.e., geosmin and MIB, produced by
bacteria (actinomycetes)
St Andrews Science Seminar October 12, 2012
Post-Harvest Slaughter
Rapid & Humane • Percussive Stunning
– MODEL SI-7 (Seafood Innovations)
St Andrews Science Seminar October 12, 2012
Growout Trial Results: Product Quality
• High condition factor (1.7) • Good fillet yield (58% skin-off & trimmed)
St Andrews Science Seminar October 12, 2012
Growout Trial Results: Product Quality
• Good fillet color (28-30) & lipid content (16%)
St Andrews Science Seminar October 12, 2012
Fillet Color Scores based on Salmo fan
St Andrews Science Seminar October 12, 2012
Flavor
Two blind taste test panels of seafood professionals in Seattle indicated preference for Freshwater Institute salmon cultured in RAS and depurated 10 days vs. commercially available ocean-raised A. salmon • Cooked flavor • Cooked smell • Cooked texture
St Andrews Science Seminar October 12, 2012
• 80% of male salmon matured early • 40% of all fish removed as early maturing
males – approximately half at 2 kg and half at 3.5 kg
• Few sexually mature females
Growout Trial Results: Early Maturing Male
Suggests use of an all female salmon or late
maturing strain for freshwater growout
St Andrews Science Seminar October 12, 2012
Moore Foundation Funded Growout Trial
• Atlantic salmon - Cascade Strain – eggs purchased from American Gold Seafood
• Jan 2011 – Eyed eggs received • March 2011 - First feeding • Aug-Sept 2011 – Photoperiod manipulated to S0 smolt • September 2011 - Moved into advanced nursery system • March 2012 – Moved into growout system
St Andrews Science Seminar October 12, 2012
Moore Foundation Trial Results to Date - Cascade Strain
St Andrews Science Seminar October 12, 2012
Moore Foundation Trial Results to Date - Cascade Strain
• Feed conversion – 1.01 feed : 1.0 gain
• Good fin condition • No sea lice • Obligate pathogens
screening will be conducted before harvest
St Andrews Science Seminar October 12, 2012
Moore Foundation Trial Results to Date - Cascade Strain
• No vaccination • No antibiotics or pesticides used at any time • No formalin used at any time • Small amount of hydrogen peroxide (H2O2)
used in the sac fry and early parr stage to treat fungus.
• Total salt used to treat fungus: 8070 lbs.
St Andrews Science Seminar October 12, 2012
Moore Foundation Trial Results to Date - Cascade Strain
• Mortality 0.8% • Culls 1.1% • Jumpers 0.2% • Total 2.1%
St Andrews Science Seminar October 12, 2012
Moore Foundation Trial Results to Date - Cascade Strain
• 37% of the population harvested Sept, 2012 – biomass at 100 kg/m3 – mean fish size at 2.64 kg. – 5.4 metric tonne (12,000 lb) – sold to a local processor for hot smoking.
St Andrews Science Seminar October 12, 2012
Moore Foundation Trial Results to Date - Cascade Strain
• Upcoming harvests of premium salmon: – mean size of 4 kg in early December 2012
• 22 months post-hatch
– biomass density will be 100 kg/m3 – harvests begin in December, run through
February, – produce another 15-18 metric tonne
• selling to Albion Fisheries
• Total Production Expected: 21-23 tonne
St Andrews Science Seminar October 12, 2012
CONCLUSIONS: Atlantic Salmon Growout Trial
• Good growth in freshwater – Harvest 8-9 months
sooner than net pens
• Good survival (90+%) & feed conv. (1.01:1 to 1.09:1)
• Density can reach 100 kg/m3
• Should use all female eggs to avoid precocious males
We don’t need seawater to farm Atlantic salmon
St Andrews Science Seminar October 12, 2012
Additional Research Needs
MINIMIZE EARLY MATURING FISH • Identify the optimum photoperiod
– 18 hr light vs. 24 hr light during 1st year (+ S0 winter)
• ASF & Moore Foundation funded study • Cascade salmon are now 60 g in S0 winter
• Identify the best seedstock for land-based closed-containment systems – Late maturing & rapid growing Norwegian strains – All female eggs & triploids – Need funding (eggs to arrive this winter)
St Andrews Science Seminar October 12, 2012
Concept Design and Cost for a 3,300 MT/yr Closed-Containment System
Brian Vinci
Growout Building 21,320 m2 (5.3 acre) Building
34,180 m3 Culture Volume 40 Tanks: 16 m dia. x 4.25 m deep 94.6 m3/min recycle flow per RAS
90 weeks production cycle to 5.0kg
Total RAS Systems $21,126,000 Processing
$1,878,000 Total Buildings $8,379,000 TOTAL ± 30%
$31,383,000
St Andrews Science Seminar October 12, 2012
Production-3,300 MT HOG
Overall density averages 48 kg/m3 Production:Biomass is 1.8 : 1
Brian Vinci
St Andrews Science Seminar October 12, 2012
Cost of Production
$3.46 per kg HOG ($3.90/kg HOG)
82% HOG ($0.11/kg eggs)
Competitive with costs in Norway
St Andrews Science Seminar October 12, 2012
Resource Metrics
Buildings – 7 acres (28,191 m2)
Land – 8 to 20 acres
Water Supply – 2,015 gpm (7.6 m3/min)
Max Weekly Oxygen (LOX) – 54,000 kg
Max Weekly Feed – 90,000 kg
Max Weekly Biosolids Captured – 28,000 kg (includes more than ~90% of TP & ~67% of TN)
Electricity – 2,250 Max kW (primary pumps + ozone generators)
St Andrews Science Seminar October 12, 2012
Assumptions
• Model assumes an all-female eggs source, w/ eggs available every three months – Could be met by Norwegian egg supplier – Not currently available in the U.S.
• Growth similar to Cascade strain at TCFFI • Costs can change with site selection due to
differences in power and oxygen costs or other factors
St Andrews Science Seminar October 12, 2012
Conclusions: Atlantic Salmon Production
• Research suggests that land-based closed-containment systems for Atlantic salmon are: – technically viable – biologically feasible, and – economically sustainable at 3000 ton/yr scale
• pilot and commercial-scale projects must demonstrate economic viability
St Andrews Science Seminar October 12, 2012
Conclusions
• Closed-containment systems have improved food security & reduced environmental impact: – Small water footprint
• Water supply is less impacted by climate change
– Efficient, with feed conversion near 1:1 – Near zero waste discharge – Reduced antibiotic & chemotherapeutic use – Zero escapees - prevent genetic impacts on natural
populations – Locate near the major markets, local production
St Andrews Science Seminar October 12, 2012
Conclusions
• Land-Based Closed-Containment Systems – Confidence in technology is increasing – Scale of investment has increased to $5-25 million/
project – Current N. American projects being built or planned
with projected capital investment of ~$50-100 million
• Atlantic salmon, Coho salmon • sea bream, yellow perch, cobia, sturgeon • Arctic char, walleye, sablefish, rainbow trout
St Andrews Science Seminar October 12, 2012
Conclusions
• North America’s annual production of food-fish within closed-containment systems could increase by 10,000 to 50,000 ton in next 5 yrs
• Global annual production increases could total 100,000’s tons within closed-containment systems in next 5 yrs – Much growth in Atlantic salmon production in
North America and China
St Andrews Science Seminar October 12, 2012
Conclusions
• Advantages of fish farming in North America – Availability of enormous soy, grain, and protein
byproducts for use as fish feed ingredients – Inexpensive electricity in some areas: $0.02-0.06/
kwh • Much cheaper than China at $0.13/kwh
– Close to major markets • Low CO2 footprint for shipping fresh product
– Skilled work force – Reliable 3-phase power