Top Banner
WATER TECHNOLOGY RAS Design Innovations and Opportunities for New Technologies Frederic Gaumet Marius Hægh
40

RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

May 13, 2018

Download

Documents

trinhkhue
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Page 1: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

WATER TECHNOLOGY

RAS Design Innovations and Opportunities for New Technologies

Frederic GaumetMarius Hægh

Page 2: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

1. Salmon industry drives RAS innovations2. Kaldnes® RAS concept3. From concept to reality4. Understand to improve5. A few innovations6. A new way to farm fish?

RAS Design Innovations and Opportunities for New Technologies

2

Page 3: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

IntroductionA necessary evolution / revolution for the salmon

industry

Page 4: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

4

Production of Atlantic salmon and trout

19990,5 millMT

20303,0 millMT

20101,0 millMT

20505,0 millMT

100% 200% 70%

Source: Almås et al. 2013.: «Verdiskaping basert på produktive hav i 2050»

What are the implications of given future prognoses?

If we assume 4,0 kg harvest per smolt this means:

‐ 750 million smolts in 2028 (15 years from now)‐ 1250 million smolts in 2048 (35 years from now)

What are the implications of the future prognosis

Page 5: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

The future of smolt production

5

To produce “super” post‐smolts under controlled environment

• Today smolts are produced up to 100‐250g max• Smolts not always adapted to salinity before transfer to sea

To increase turnover and productivity of fattening sea sites

• By shortening production cycle on sea• By increasing nb of batches per year• By optimizing sea based operation (feeding/handling/etc.)

To answer environmental concerns and health/welfare issues on salmon

• Environmental impact of net pens• Sea lice issues• Diseases spreading• Smolt and young adult escapees

Page 6: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

The most important message is HERE:

6

VF3 akk

00,5

11,5

22,5

3

Lok 1

Lok 1

Lok 2

Lok 2

Lok 2

Lok 2

Lok 3

Lok 3

Lok 3

Resirk

Resirk

Resirk

Resirk

Resirk

Lok 4

Lok 5

Lok 5

Lok 6

Lok 6

Lok 7

Lok 7

Lok 7

VF3 akk

00,5

11,5

22,5

3

Lok 1

Lok 1

Lok 2

Lok 2

Lok 2

Lok 2

Lok 3

Lok 3

Lok 3

Resirk

Resirk

Resirk

Resirk

Resirk

Resirk

Resirk

Resirk

Resirk

Resirk

Lok 4

Lok 5

Lok 5

Lok 6

Lok 6

Lok 7

Lok 7

Lok 7

Lok 5

Lok 5

Lok 6

Lok 6

Lok 7

Lok 7

Lok 7

% døde.

0,002,004,006,008,00

10,0012,0014,0016,00

Lok 1

Lok 1

Lok 2

Lok 2

Lok 2

Lok 2

Lok 3

Lok 3

Lok 3

Resirk

Resirk

Resirk

Resirk

Resirk

Lok 4

Lok 5

Lok 5

Lok 6

Lok 6

Lok 7

Lok 7

Lok 7

% døde.

0,002,004,006,008,00

10,0012,0014,0016,00

Lok 1

Lok 1

Lok 2

Lok 2

Lok 2

Lok 2

Lok 3

Lok 3

Lok 3

Resirk

Resirk

Resirk

Resirk

Resirk

Resirk

Resirk

Resirk

Resirk

Resirk

Lok 4

Lok 5

Lok 5

Lok 6

Lok 6

Lok 7

Lok 7

Lok 7

Lok 4

Lok 5

Lok 5

Lok 6

Lok 6

Lok 7

Lok 7

Lok 7

Smolt produced in RAS show very good performances when placed in growout sea pen farms. Superior growth and lower mortality.

Post‐smolts performances after transfer to sea (the first 3 months in net pens)

SGR (%/day)

Mortality (% over a 3 months period)

Page 7: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

Moving forward to more sustainability

Industry Challenge

7

Land and water availability

Animal welfare and performance

Operational conditions and technical risk

Environmental impact, sustainability and regulatory and 

consumer risks

Profitability

RAS’s response

Significantly reduced water consumptionLess land due to reduced footprint

Healthier and more disease resistant fishBetter animal welfare due to better overall conditions

Reduced vulnerability towards external factorsImproved control over biological performanceReduced technical risk

Reduced costs of installation and operationLower energy costsReduced technical, political and consumer risks

Reduced impact and load on the natural environmentSludge and effluent recoveryReduced physical and carbon footprintsReduced regulatory and consumer risks

Page 8: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

Compact and energy efficient designKaldnes® RAS

Page 9: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

9

Kaldnes ® RAS – Compact and energy efficient design

Krüger Kaldnes

1122

33

44

55

6677

88

9910

13

11

12

1. Inspection and access opening2. Bioreactor 23. Bioreactor 14. Air blowers in sound silencer chamber5. Drum filter 60 micron6. Drum filter 20 micron7. Drum filter 60 micron8. Pumps9. Bypass and return water10. CO2 and N2 stripper11. Collection pipe inlet water12. Collection pipe outlet water13. Deepshaft oxygen cone

Page 10: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

10

Kaldnes® RAS – Video

Krüger Kaldnes

Page 11: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

Design innovationKaldnes® RAS in Practice

Page 12: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

12

Design innovation - Kaldnes® RAS in Practice

Krüger Kaldnes

Largest aquaculture recycling center in EuropeCutting edges technologyBoth fresh‐ and seawater

Nofima Research station – Sunndalsøra (NO)

Page 13: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

13

Design innovation - Kaldnes® RAS in Practice

Krüger Kaldnes

Capacity over 5 Million smolts/yearTotal rearing volume 4250 m3Complete process design and delivery by Krüger Kaldnes

MARINE HARVEST, DALSFJORD – Grow out

Page 14: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

14

Design innovation - Kaldnes® RAS in Practice

Krüger Kaldnes

Capacity 3 Millions smolts/yearTotal rearing volume 3000 m3Complete process design and delivery by KrügerKaldnes

Sundsfjord Smolt AS

Page 15: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

15

Design innovation - Kaldnes® RAS in Practice

Krüger Kaldnes

Marine Harvest – Steinsviko Capacity of 5,3 mill smolt up to 250g/year

o 3 department

o 9600 m3 total rearing volume

o 10MT total daily feeding

Page 16: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

16

Design innovation - Kaldnes® RAS in Practice

Krüger Kaldnes

Marine Harvest – SteinsvikFirst eggs to be introduced in February 2015 !

Page 17: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

Understand to improveRecirculating Aquaculture System (RAS)

Page 18: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

Our Development Strategy

Strong focus on understanding water quality and technologicalperformance to develop the best solutions available

18Krüger Kaldnes

o Development and documentation of:o Energy efficient production

o Biosecurity and plant management

o Fine particle control and water quality polishing

o Optimization of biological water treatment

o Low energy/low head gas control in RAS treatment loop

o Efficient and sustainable solutions for sludge treatment and

handling

Page 19: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

0%10%20%30%40%50%60%70%80%90%100%

5,0

6,4

8,0

10,1

12,7

16,0

20,2

25,4

32,0

40,3

50,8

64,0

80,7

101,7

128,1

161,4

203,4

256,3

Cumulative volume pe

rcen

tage

Particle size (µm)After DF

Before DF

Before DFo PSD covers full particle size rangeo Dominating particle size are particles >300 µmo 75% > 60 µm

Master Thesis – Timo Rosche - 201419

Impact of the Drum Filter on PSD

FIGURE 28: DISTRIBUTION OF PSDS  (RELATIVE VOLUME PERCENTAGE) BEFORE AND AFTER DRUM FILTRATION. WATER SAMPLES ANALYZEDWERE MIXED SAMPLES FROM BEFORE  (N=4)/ AFTER  (N=4) THE 3 HYDROTECH DRUM FILTER WITH 2 X 60 µM  (85 % OF FLOW) AND 1 X 30  (15 % OF FLOW) µM FILTER GAZE. 

FIGURE 29: DISTRIBUTION OF PSDS  (CUMULATIVE VOLUME PERCENTAGE) BEFORE AND AFTER DRUM FILTRATION. WATER SAMPLES ANALYZEDWERE MIXED SAMPLES FROM BEFORE  (N=4)/ AFTER  (N=4) THE 3 HYDROTECH DRUM FILTER WITH 2 X 60 µM  (85 % OF FLOW) AND 1 X 30  (15 % OF FLOW) µM FILTER GAZE. 

0%

5%

10%

15%

20%

25%

30%

35%

40%

Relativ

e volume pe

rcen

tage

 (%)

Lower particle size class (µm)After DF

Before DF

DF 1 (30µm)

DF 2+3 (60µm)

After DFClear reduction of upper particle size range97% of all particles < 60µm83% < 30µm

Clear effect of DF ‐ PSD changed from dominatingbig particles to dominating fine particle.

Testing and validation - Kaldnes® RAS

Page 20: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

Testing and validation - Kaldnes® RAS

20Krüger Kaldnes

Total ammonia nitrogen (TAN) was in the range 0,4 – 0,6 mg/L in both test periods. 

This shows that the nitrification is stable and efficient at thetested feed loads (900 – 1100 kg/d).

Note that the CO2 stripper also contribute considerably to total nitrification capacity inthe system.

Page 21: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

CO2 og N2- removal

21Krüger Kaldnes

G:L ratio 5:1Neg. pressure 0,3 mVs increase capacity

N2 saturation

Page 22: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

Oxygenation-Deepshaft

22Krüger Kaldnes

• Greatly reduced energy costs• Pressure 7,5‐10m (0,7‐1 bar).

• Dissolution efficiency 96‐98 % in freshwater

Page 23: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

Advanced Oxydation Technology (AOT)New Technologies

Page 24: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

24

New Technologies – AOT

Krüger Kaldnes

o Utilizes the most powerful oxidants in nature – free radicals

o Chemical-freeo Inspired by nature´s own process to

degrade organic materialso Nothing added to the processo No risk for overdosingo Low energy consumptiono Decreases turbidity

AOT in RAS systemsAOT Function:

Page 25: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

Kaldnes® RAS - TerflexNew Technologies

Page 26: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

26

New Technologies - Kaldnes® RAS - Terflex

Krüger Kaldnes

Side stream Ultrafiltration System at 0,02 micronLarge scale trial at NofimaSignificant impact on water qualityHigh membrane efficiencies

Fine solids and colloidal particle removal

Page 27: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

Anita™ MoxNew Technologies

Page 28: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

28

New Technologies - Anita™ Mox

Krüger Kaldnes

The key  conversion in the ANITA™ Mox is nitrogen removal through anaerobic ammonium oxidation

Anaerobic ammonium oxidation (Anammox)

NH4+ + NO2

‐ ‐>  N2  + 2H20

Features:• Less O2  (≈ 60%)• No carbon needed• Less CO2 production• Less sludge production• Less alkalinity consumption (≈ 50%)

Disadvantages:• Slow growth rate, doubling time 11‐13 

days ‐ long start‐up periods• Necessary to have a long SRT (Biofilm)• Nitrite accumulation if process is 

inhibited

Nitryfying biofilm vs. Anammox biofilm

Page 29: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

New MBBR Media ?New Technologies

Page 30: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

Z - The new dimension of MBBR

Page 31: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

Biofilm surface area at different biofilm thickness

Protected surface area vs biofilm surface area

31

Page 32: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

When oxygen and other reactants are consumed, a redox gradient is formed in the biofilm

The importance of the redox gradient

32

Carrier

Bulk Liquid

Oxygen

BoundaryLayer

Anaerobic Anoxic Aerobic

Page 33: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

The principle of biofilm control

33

1

2

3

4

o Carrier design for self-control of biofilm thickness

Page 34: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

Possibilities with biofilm control

Eliminating variations due to changes in biofilm thicknessEliminating limitations due to clogging biofilmFacilitates engineered and controlled redox gradients allowingtailor-made design for specific reactions

Thin, completely aerobic Aerobic and anoxic Thick aerobic, anoxic, anaerobic

Selenium removalExamples:Nitrification with organicload

ANITA Mox

Page 35: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

The optimized carrier

Combines a controlled biofilm and design for maximum mass transferIs different for different applications

Page 36: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

A New Way to Produce FishRAS 2020 Technology

Page 37: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

RAS2020 : Or how to combine RW fish handling efficiency and circular tanks hydrodynamics

37Krüger Kaldnes

A capacity of 1200MT salmon 4‐5 kg/yearwithin a 2700 m2 building

Page 38: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

Compact – no piping – built in 6 months

38Krüger Kaldnes

1. Fish tanks with movable compartments2. Transport Channel outlet3. Inlet weir for Drumfilters4. UV-treatment of partial stream5. MBBR reactor6. CO2 and N2 stripper7. Propeller pumps into level weir8. Inlet channel & circulation propellers9. Purging tank10. AOT treatment for purging11. Denitrification Reactor

FootprintMBBR 160m2

Tank 580m2

Rearing Vol 2680m3

Page 39: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

Assumptions and specs.

39Krüger Kaldnes

Page 40: RAS Design Innovations and Opportunities for New … · RAS Design Innovations and Opportunities for New Technologies ... RAS Design Innovations and Opportunities for New Technologies

WATER TECHNOLOGY

Thank you