A Guide to Recirculation Aquaculture - Part 5

Water temperature regulation 

Maintaining an optimal water temperature in the culture system is most important as the growth rate of the fish is directly related to the water temperature. Using the intake water is a fairly simple way of regulating the temperature from day to day. In an indoor recirculation system the heat will slowly build up in the water, because energy in the form of heat is released from the fish metabolism and the bacterial activity in the biofilter. Heat from friction in the pumps and the use of other installations will also accumulate. High temperatures in the system are therefore often a problem in an intensive recirculation system. By adjusting the amount of cool fresh intake water into the system, the temperature can be regulated in a simple way.

If cooling by the use of intake water is limited a heat pump can be used. The heat pump will utilize the amount of energy normally lost in the discharge water or in the air leaving the farm. The energy is then used for cooling the circulating water inside the farm. A similar way of lowering heating/cooling cost can be achieved by recovering the energy by the use of a heat exchanger. Energy in the discharge water from the farm is transferred to the cold incoming intake water or vice versa. This is done by passing both streams into the heat exchanger where the warm outlet water will lose energy and heat up the cold intake water, without mixing the two streams. Also on the ventilation system a heat exchanger for air can be mounted utilizing energy from the out-going air and transferring it to the in-going air, thereby reducing the need for heating significantly. 

In cold climates heating of the water can be necessary. The heat can come from any source like an oil or gas boiler and is, independent of energy source, connected to a heat exchanger to heat the recirculated water. Heat pumps are an environmental friendly heating solution, and can utilize energy for heating from the ocean, a river, a well or the air. It can even be used to transfer the energy from one recirculation system to another, and thereby heat one system and cool another. Usually it utilizes energy from e.g. the ocean using a titanium heat exchanger, moves the energy to the recirculation that is calling for heating and releases the heat through another heat exchanger.

Pumps 

Different types of pumps are used for circulating the process water in the system. Pumping normally requires a substantial amount of electricity, and low lifting heights and efficient and correctly installed pumps are important to keep running costs at a minimum. 

The lifting of water should preferably occur only once in the system, whereby the water runs by gravity all the way through the system back to the pump sump. Pumps are most often positioned in front of the biofilter system and the degasser as the water preparation process starts here. In any case, pumps should be placed after the mechanical filtration to avoid breaking the solids coming from the fish tanks. 

Calculation of the total lifting height for pumping is the sum of the actual lifting height and the pressure losses in pipe runs, pipe bends and other fittings. This is also called the dynamic head. If water is pumped through a submerged biofilter before falling down through the degasser, a counter pressure from the biofilter will also have to be accounted for. Details on fluid mechanics and pumps are beyond the scope of this guide.

Figure 2.18 Lifting pumps type KPL for efficient lifting of large amounts of water. Lifting pumps are often used for pumping the main flow in the recirculation system. Correct selection of pump is important to keep the running costs down. Frequency control is an option to regulate the exact flow needed depending on the fish production. H is the lifting height and Q is the volume of water lifted. Source: Grundfos

 

Figure 2.19 Centrifugal pumps type NB for pumping water when high pressure or high lifting heights are needed. The range of centrifugal pumps is wide, so these pumps are also efficiently used for pumping at lower lifting heights. Centrifugal pumps are often used in recirculation systems for pumping secondary flows as for example flows through UV systems or for reaching high pressure in oxygen cones. H is the lifting height and Q is the volume of water lifted. Source: Grundfos

The total lifting height in most intensive recirculation systems today is around 2-3 metres, which makes the use of low pressure pumps most efficient for pumping the main flow around. However, the process of dissolving pure oxygen into the process water requires centrifugal pumps as these pumps are able to create the required high pressure in the cone. In some systems, where the lifting height for the main flow is very low, the water is driven without the use of pumps by blowing air into aeration wells. In these systems the degassing and the movement of water are accomplished in one process, which makes low lifting heights possible. The efficiency of degassing and moving of water is however not necessarily better than that of pumping water up over the degasser, because the efficiency of aeration wells in terms of using energy and the degassing efficiency is lower than using lifting pumps and stripping or trickling the water. 

Monitoring, control, and alarms

Intensive fish farming requires close monitoring and control of the production in order to maintain optimal conditions for the fish at all times. Technical failures can easily result in substantial losses, and alarms are vital installations for securing the operation.

In many modern farms, a central control system can monitor and control oxygen levels, temperature, pH, water levels and motor functions. If any of the parameters moves out of the preset hysteresis values, a start/stop process will try to solve the problem. If the problem is not solved automatically, an alarm will start. Automatic feeding can also be an integrated part of the central control system. This allows the timing of the feeding to be coordinated precisely with a higher dosage of oxygen as the oxygen consumption rises during feeding. In less sophisticated systems, the monitoring and control is not fully automatic, and personnel will have to make several manual adjustments. 

Whatever the case, no system will work without the surveillance of the personnel working on the farm. The control system must therefore be fitted with an alarm system, which will call the personnel if any major failures are about to occur. A reaction time of less than 20 minutes is recommended, even in situations where automatic back-up systems are installed.

 

Figure 2.20 An oxygen probe (Oxyguard) is calibrated in the air before being lowered into the water for on-line measurement of the oxygen content of the water. Surveillance can be computerized with a large number of measuring points and alarm control.

Emergency system 

The use of pure oxygen as a back-up is the number one safety precaution. The installation is simple, and consists of a holding tank for pure oxygen and a distribution system with diffusers fitted in all tanks. If the electricity supply fails a magnetic valve pulls back and pressurized oxygen flows to each tank keeping the fish alive. The flow sent to the diffusers should be adjusted beforehand, so that the oxygen in the storage tank in an emergency situation lasts long enough for the failure to be corrected in time.

Figure 2.21 Oxygen tank and emergency electrical generator

To back up the electrical supply, a fuel driven electrical generator is necessary. It is very important to get the main pumps in operation as fast as possible, because ammonia excreted from the fish will build up to toxic levels when the water is not circulating over the biofilter. It is therefore important to get the water flow up and running within an hour or so.

Intake water 

Water used for recirculation should preferably come from a disease-free source or be sterilised before going into the system. In most cases it is better to use water from a borehole, a well, or something similar than to use water coming directly from a river, lake or the sea. If a treatment system for intake water needs to be installed, it will typically consist of a sand filter for microfiltration and a UV or ozone system for disinfection.