“practical experience with the design, construction …
TRANSCRIPT
“PRACTICAL EXPERIENCE WITH THE
DESIGN, CONSTRUCTION AND MANAGEMENT OF A SUPER INTENSIVE
SHRIMP CULTURE SYSTEM IN USA”
LESLIEVKNOESEN&LEANDROCASTRO
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FARMERFROMFLORIDAUSA
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EB-5FOREIGNINVESTMENTPROGRAM• Permanentresidence–greencards• Implementation–RegionalCenters• BuildingProjectsemployingAmericans• Allprojectsatrisk
FLORIDAAQUACULTUREPROJECT• BiggestindoorshrimpfarminUSA• Largestbuildingsofit’skind• 400mlong,4footballfields• Hatchery,nursery• Deepwellforseawater,750m
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USA SHRIMP MARKET*USAranks3rdlargestseafoodconsumingnation.
*Percapitaconsumptionis25%ofallseafood.(NationalFisheries
2015)
*30yearsago80%ofshrimpconsumedwasfromdomesticsources.
*Today90%isimportedatavalueof$5billion.
*10%isfromfarmedandwildsources.(USDAERS2016)
*ShrimpisUSA’sfavoriteseafood.
*Approx.1.6billionpoundsannually.(+-4.5poundspercapita)
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Table1.Waterusagecomparisonofpond–basedshrimpproductionsystemswithsuperintensiverecirculatingtank–basedsystems.(Hopkins1993)
Typeofproductionsystem
DensityKg/cu.m
DailywaterExchange(%dailyvolume)
LengthofCropcycledays
Waterusage/kgshrimpharvested
Waterusage/kgcomparedtoextensive%
Waterusage/kgcomparedtoultraintensive
Extensive
Semi-intensive
Intensive
Super-intensive
0.1
0.3
1.5
5
5%
10%
0.5%
0.25%
120
120
120
120
70
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1.1
0.26
100%
61,9%
1.5%
0.4%
26.923%
16.667%
410%
100%
• Traditionalshrimpproduction,acresofoutdoorponds.• Highvolumesofnutrientrichwaterexchange.• Directaccesstooceanorestuarywater.• Dangertoenvironmentandnotsustainable
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RECIRCULATING AQUACULTURE SYSTEMS (RAS)
• RASTechnologyhasadvancedconsiderablyinrecentyears.• Offersamuchhigherlevelofcontrolrelativetoopensystems.• Allowsopportunitytoproduceshrimpwithminimalecologicalimpact.• Ofteninareaswheretraditionalaquaculturewouldnotbepossible.• Givespotentialtoreducepathogenexposure,butproducesuniqueshrimphealthchallenges.
• Thisisaclosedsystemwithfluctuatingbiomassandnutrientflow.• Goodhealthwithinthesystemdependsuponprovidingagoodenvironmentandmanagingit.
• RASrequirestotalcontroloftheenvironmentwithproperequipmentdesign,specification,skilledmanagementandfarmhealthmanagement.
• NOFARMISEVERINBALANCEORPATHOGENFREE.
ZERO DISCHARGE RAS SYSTEM
• Thesuperintensiveapproach–highvolumes,smallfootprint.
• Nitrogenouswastescontrolledin-situbymix-o-trophicbio-flocs.
• Solidscontrolledbysettlingtank,noadditionalenergyinput.
• Aeration,circulatingdonebypumpandnozzlesystem.
• Sustainableandefficienttreatmentofwaterallowsfarmerstomeetrigorousdemandsofenvironmentalstewardship.
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THEBUILDING
• ¼milelong,4footballfields
• Area182000sq.ft.
• Volume2500000cubicft.
• 4.5milliongalsseawater
• Raceways300’x30’x5’deep
DESIGNCONSIDERATIONS.• Closedenvironment
• Marineatmosphere,highlycorrosive• Florida+80%humiditytempupto40C
• Heating,ventilationandcooling• Volumeinside2,500,000cubicfeet
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• Barn160’x90’–14000sq.ft.• 8racewaysat25000gals.Each.• 200000gals.perbuilding(750Kliters)• Raceways64’x16’x4’deep.• Postlarvaestocking400000.• Max.production30000lbs.pa.
ITHUBASHRIMPFARM
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POLEBARNBUILDING MACHINERY+MANPOWER POLYURETHANESPRAYFOAM
POLEFOUNDATION PLACINGPOLES APPLYINGSPRAYFOAM
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RETROFITWAREHOUSE GREENHOUSE HOMEMADE
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RACEWAYDESIGNS
SANDBAGS SANDBAGS+LUMBERBOARDSRACEWAYSTIEDTO
STRUCTUREPLYWOODSHEETS COMPLETEDRACEWAY
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LARGERACEWAYS
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RACEWAYLINERCUTTINGTOSHAPE GEOFABRICUNDERLINER
HEATGUNANDWELDING COMPLETEDRACEWAYANDBAFFLE
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AERATION&CIRCULATION
PUMPSANDPLUMBING PIPEWORK
NOZZLELAYOUT VFDCONTROLPANEL
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CIRCULATION1
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CIRCULATION2
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• VENTURIAERATIONNOZZLE
• STANDARDPLUMBINGPARTS
• HOMEASSEMBLED
• COSTLESSTHAN$10EACH
• UPTO17%MOREAIRINJECTIONTHANTHEMARKETABLEONE
VENTURINOZZLE
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• Dailyofftake0.25%–0.50%
• Adjustedbyvalveonofftake
• Skimtopasrequired• Drainsolidsfrombottom
everyotherweekasrequired
• Solidsdrainedintofacultativepondoutside
• Onlyintouseafterapprox.60days
SETTLINGTANK
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PLUMBING
UNDERGROUNDDRAINAGE GOODWORKMANSHIP STANDARDPVCFITTINGSCIRC.ANDAERATION SIMPLEANDEASYACCESS FRESHANDSEAWATER
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MANAGEMENT OF THE SYSTEM
• Managementisaboutfollowingtheestablishedprotocols.• Setuptaskschedulesandtheymustbefollowedandlogged.• Thelifeofthesystemisinthewater.• Testing,thesecouldbedaily,weeklyorondemand.• Lookforanychangesandreportthem.• Neglectthewaterandthesystemwillcrash.• EverythingistryingtomaintainthebalanceoftheBio-floc.• Watermanagementbothindoorsandoutdoors.• Animalhusbandry,takingcareoftheanimals.• Understandingthenatureandbehaviorofshrimp.• Watchingandrecordinganybehaviorchanges.• Establishingandfollowingbio-securityprotocols.
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Parameter FrequencyTested
IdealValue
DissolvedOxygen Daily Above5mg/L
Temperature Daily 29-31C
pH Daily 7.3-7.5
Salinity Daily 30–32ppm
TAN 2/week 0–0.5ppm
Nitrite 2/week Lessthan1ppm
Alkalinity 2/week 170-200
TSS 2/week 150–200mg/L
SS 2/week 15
CarbonDioxide 1/week Lessthan10mg/L
Nitrate OnDemand Lessthan200ppm
WATERTESTING&Management
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DAILY LOG
Pond SS Amm. Nitr. Alka. PH. DO. Temp. Sal. Mol. Bicarb Mort Av.Wgt
No ml/l mg/l mg/l ml/l Mg/l C Ppt. L Kg No grams
1 5.5 1.0 0.05 200 7.8 6.10 28.4 22.5 1.0 0 1 1.2
2 - 0.5 0.03 184 8.25 6.0 28.0 24.8 0.5 1.0 0 1.4
3 7.0 0.5 0.04 194 8.1 6.1 29.3 23.7 1.0 0 13 5.5
4 8.0 0.5 0.03 200 8.1 6.3 28.7 23.8 1.0 0 2 6.0
5 - 0.1 0.05 200 8.4 6.3 27.8 24.8 0.5 0 0 12.6
6 5.5 0.03 0.05 200 8.3 6.0 28.1 21.5 1.0 0 1 13.5
7 - 1.0 0.04 200 8.3 5.85 27.7 24.9 .05 0 0 20.0
8 - 0.1 0.05 170 8.4 5.9 27.8 25.3 0.5 1.0 0 19.1
Comments:*postlarvaelookgood,gutsstartingtofill.“Poop”developinginwater,swimmingactively.*RW#4molting,allshrimpveryactive.
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Date Age Population Survival Av.Wt.g Growth/week Feedtype DailyFeedKg EZ(mL)
05/10/17 0 40,000 100.00% 0.0032
05/11/17 1 39,846 99.62% 0.0049 0.1
05/12/17 2 39,692 99.23% 0.0067 0.1
05/13/17 3 39,538 98.85% 0.0090 0.1
05/14/17 4 39,385 98.46% 0.0114 0.1
05/15/17 5 39,231 98.08% 0.0137 0.1
05/16/17 6 39,077 97.69% 0.0164 0.05
05/17/17 7 38,923 97.21% 0.0213 0.0049 0.03
05/18/17 8 38,769 96.92% 0.0264 0.0051 0 0.18
05/19/17 9 38.615 96.54% 0.0324 0.0060 0 0.18
05/20/17 10 38,462 96.15% 0.0396 0.072 0 0.18
05/21/17 11 38,308 95.77% 0.0470 0.074 0.1 0.36
05/22/17 12 38,154 95.38% 0.0545 0.075 0.1 0.36
05/23/17 13 38,000 95.00% 0.0619 0.074 0.1 0.50
05/24/17 14 37846 94.62% 0.0734 0.115 0.1 0.50
Raceway1StockingDate:05/10/17
StockingNumber40000StockingWeight0.0032g
FinalSurvivalExp.50%
FEEDCHART
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GROWOUT AND BIO-SECURITY PROTOCOLS
• Sanitizehandsandarmsuponentrytoproductionarea.• Chlorineandalcoholonly,noaerosolsandbugspray!• Donotshareitemsbetweenraceways.• Whenweighing,cleanscales,beakersandequipment.• Ifyouspillfeed,cleanitup.• Ifyouuseequipmentcleanitafteruseandreturnit.• Ifacontainerordispenserisempty,fillit.• Taketrashoutwhenfull.• Donotputdeadshrimpintrashcans.• Donotleavenetsinchlorinebathsmorethan5mins.• Ifyouuseamicroscope,clean,turnthelightoffandcover.• Donotremoveglasswarefromwaterqualitylab.• Ifyouareunsureask!!!
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FRUITSOFHARDWORKANDPERSERVERENCE
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PRODUCTIONCOSTSITEM 1BARN 2BARNS 1BARN3PHASE 2BARN3PHASE
LABOR $1.90 $1.45 $1.16 $1.16
FEEDFCR1.5 $1.00 $1.00 $1.00 $1.00
POWER $0.60 $0.60 $0.60 $0.60
ADDITIVES $0.25 $0.25 $0.25 $0.25
MISCELLANEOUS $0.25 $0.25 $0.25 $0.25
PRODUCTIONLBSPerMonth 2500 5000 7500 15000
HARVESTSPERYEAR 24 48 36 72
GROWOUTDAYS 120 120 90 90
TOTALCOST $4.00 $3.55 $3.26 $3.26
• Growout120daysincluding30daynurseryphase
• Growout90dayswithnurseryphaseseparate
• Harvestbasedon6Kg/cubicmeter• Raceways95cubicmeters
• Laborrate$15.00perhour• 1Barn1.5people48hoursaweek120day• 2Barns2.5people48hoursaweek• 1Barn3.0people48hoursaweek,90day• 2Barns6.0people48hoursaweek
