James M. Ebeling, Ph.D. Research Engineer Aquaculture Systems Technologies, LLC Michael B. Timmons, Ph.D. Professor Dept. of Bio. & Environ. Eng. Cornell University HYDROPONICS • • • RAFT NFT RECIPROCATING 2015 Engineering Design & Water Quality HYDROPONICS • FLOATING RAFT • NFT • MEDIA BED • DRIP 2015 Greenhouse Crop Production & Engineering Design Short Course Fish Culture Tank “Anything that holds water” 2015 Greenhouse Crop Production & Engineering Design Short Course Fish Culture Tank “Anything that holds water” 2015 Engineering Design & Water Quality Fish Culture Tank 2015 Greenhouse Crop Production & Engineering Design Short Course Fish Culture Tank 2015 Greenhouse Crop Production & Engineering Design Short Course Fish Culture Tank ! 2015 Greenhouse Crop Production & Engineering Design Short Course Fish Culture Tank 2015 Greenhouse Crop Production & Engineering Design Short Course Fish Culture Tank 2015 Greenhouse Crop Production & Engineering Design Short Course Fish Culture Tank “Cornell type” Dual-Drain Culture Tanks” "RULE OF THUMB" Dual-Drain Design Dia:Depth = 3:1 to 6:1 15 to 25% through center drain 75 to 85% through sidewall discharge 2015 Engineering Design & Water Quality Fish Culture Tank HRT = Hydraulic Retention Time Drain lines vs. Pumped Return Lines "RULE OF THUMB" Circulation Fry/Fingerlings – 15 to 30 Min HRT Growout – 30 to 45 min HRT Broodstock – 60 min HRT Purging – 1 to 2 Tank exhanges per day Maximum Flow (gpm) Pipe Dia (inches) Drain Line (1 to 2 fps) Pumped Return (< 5 fps) 1/2 3/4 1 1.5 2 3 4 6 1 2 5 10 20 45 75 150 5 10 15 30 50 125 200 500 2015 Engineering Design & Water Quality Fish Culture Tank Weight = function (length)3 3 inches 6 L Wtlbs CF 10 Growth = function (Temperature) Inches T Tbase Growth month TU base "RULE OF THUMB" Trout Tilapia Perch Tbase 32 65 50 TUbase 28 15 25 Tmax 72 85 75 Weight vs Length • CFtrout = 400 • CFtilapia = 760 • CFperch = 490 • CFstriped bass = 720 2015 Engineering Design & Water Quality Fish Culture Tank Fish Culture Density Ddensity L C density "RULE OF THUMB" Fish Culture Density (at harvest) Ddensity Density in kg/m3 (lbs/ft3) L Length of fish in cm (inches) Cdensity tilapia: 0.24 for L in cm (1.5 for L in inches) trout: 0.32 (2.0) perch: 0.40 (2.5) hybrid striped bass: 0.45 (2.8) 2015 Engineering Design & Water Quality • Swirl separators/ Radial Flow Clarifers "RULE OF THUMB" Radial FlowDesign Surface-loading rate for the radial-flow settler 4.6 gpm/ft2 of settling area 2015 Engineering Design & Water Quality 75-90% Suspended Solids • Screen Sludge filtration • rotating microscreens • horizontal screen • vertical screen • Pressurized bead filters outlet • Pressurized sand filters P • Bag filters inlet emergency drain 2015 Greenhouse Crop Production & Engineering Design Short Course • Screen filtration • Pressurized bead filters Propeller Washed Bead Filter Bubble Washed Bead Filter "RULE OF THUMB" Suspended Solids Capture Design • • Bead Filter – 5 to 6 lbs of feed per flush per ft3 of media Screen Filters – see manufacturer recommendations 2015 Engineering Design & Water Quality • Foam Fractionation • Protein Skimmers Fine & Dissolved Solids Removal Sludge "RULE OF THUMB" Foam Fractionation Tank Volume treated every 2 to 4 hours 2015 Greenhouse Crop Production & Engineering Design Short Course 75-90% Suspended Solids Sludge 2015 Greenhouse Crop Production & Engineering Design Short Course Solids Disposal • Land application By-Product NOT a Waste Stream • Aquaponics • GeoTextile Bags • Composting 2015 Engineering Design & Water Quality 75-90% Suspended Solids Sludge 2015 Greenhouse Crop Production & Engineering Design Short Course 75-90% Suspended Solids Sludge "RULE OF THUMB" Suspended Solids Capture Design Bead Filter – 5 to 6 lbs of feed per ft3 of media 2015 Greenhouse Crop Production & Engineering Design Short Course 75-90% Suspended Solids Sludge 2015 Greenhouse Crop Production & Engineering Design Short Course Sludge By-Product NOT a Waste Stream • GeoTextile Bags • Land application • Composting • Aquaponics 2015 Greenhouse Crop Production & Engineering Design Short Course Biofiltration / Nitrification Ammonia Oxidizing Bacteria 2 NH4+ + OH - + 3 O2 2 H + + 2 NO2- + 4 H2O Ammonia Nitrite Nitrite Oxidizing Bacteria 2 NO2 + 1 O2 2 NO3Nitrite Nitrate "RULE OF THUMB" Nitrification of 1 g of ammonia-nitrogen 1 KG FEED ABOUT 0.03 KG AMMONIA • Yields – 5.93 g of carbon dixoide • Consumes – 4.57 g of oxygen and 7.14 g alkalinity 2015 Engineering Design & Water Quality Moving Bed Biofilter Bead Bioclarifiers "RULE OF THUMB" MBBR Design • • • • • • 17.14 g TAN/ft3 /day curler media @ 25 to 30 Deg C 13.26 g TAN/ft3 /day @ 15 to 20 Deg C 10.14 g TAN/ft3 /day @ 5 to 10 Deg C 3 to 5 min HRT 50% fill factor – max 65% Air flow: 0.125 scfm/ft3 of reactor About 1 g TAN / m2 of media per day or ~ 500 to 1000 g per cubic meter per day 2015 Engineering Design & Water Quality “RULE OF THUMB” 1 KG FEED ABOUT 1 KG OXYGEN 2015 Engineering Design & Water Quality 2015 Engineering Design & Water Quality Aeration Air/Oxygen Aeration Systems Air Stones, Packed Towers Oxygenation Systems Micro-Diffusers, Speece Cones "RULE OF THUMB" 2015 FEED Greenhouse Crop Production 1 KG 0.65 TO 1.00 KG OF O2 & Engineering Design Short Course • Ozone • Disinfection Ultraviolet radiation "RULE OF THUMB" UV • 30 mW-sec/cm2 • 10-30 second contact times 2015 Greenhouse Crop Production & Engineering Design Short Course Monitoring & System Control Continuous Periodically • • • • • • • • • • • DO Level Flow Temperature Air pressure pH NH3 NO2 NO3 CO2 Alkalinity Phone Dialer It takes only one mistake to KILL EVERYTHING IN YOU FACILITY!!!! 2015 Greenhouse Crop Production & Engineering Design Short Course The most sophisticated monitoring and alarm system is an attentive human operator! MONITORING & SYSTEM CONTROL Water Level Local audible alarms for Low and High Water Level Alarm Low Water Level High Water Level Low Water Level 2015 Engineering Design & Water Quality Loss of Oxygen • • More fish are probably lost in recirculation systems due to lack of oxygen than to any other single cause! (actually, draining the tank unintentionally is the number one reason) normally open, electrically operated solenoid valve A three tier emergency oxygen supply is not an extravagance (Just ask NASA!) 2015 Engineering Design & Water Quality Monitoring & System Control Sensaphone WEB600 Based Monitoring System Sensor Inputs: 6 Universal Inputs • Normally Closed/Normally Open Dry Contacts • 2.8 and 10K Thermistors for Temperature • 4-20 mA Current Loop for external sensors, pH, EC, DO Alarm Notification Methods: E-mail, text messages Web page Eight alarm levels, 8 programmable user profiles Data Logging: 32,000 samples (date and time stamped) from every second to monthly Monitoring & System Control 2015 Greenhouse Crop Production & Engineering Design Short Course 2015 Greenhouse Crop Production & Engineering Design Short Course • Water Quality Lab • Storage - Feed, Chemicals, Product • Equipment Storage • Staff Support • Back-up Generator • Quarantine Area • Waste Disposal 2015 Greenhouse Crop Production & Engineering Design Short Course 48" top by 39" bottom diameter x 25" depth with 20" of water PolyTank PT-4825 2 ft x 2 ft x 3 ft deep Fiberglass Sump Sequence Model 1000 3300SEQ21 SEQ Sump UV Drain To Raft System BBF-4 cuft BioClarifier Airline Backwash Drain 2015 Engineering Design & Water Quality Unless You’re a Fish, You Can’t Tell By Sticking Your Fin in the Water! Critical Parameters • dissolved oxygen • temperature • pH • un-ionized ammonia • nitrite • nitrate • carbon dioxide • alkalinity • solids 2015 Engineering Design & Water Quality • CO2 and dissolved oxygen concentrations • pH versus ammonia-nitrogen concentration • Temperature and growth rate and health 2015 Engineering Design & Water Quality Too much is definitely better than too little! Amount of water needed will depend on: • species • density • management practices • production technology • degree of risk one is willing to accept “Rule of Thumb” 100% water exchange of total system volume per day (good operators will do 3 to 20% per day) 2015 Engineering Design & Water Quality • Groundwater • Surface Water • Municipal Water Supplies 2015 Engineering Design & Water Quality Advantages: • Constant Temperature Disadvantages: • Dissolved H2S and CO2 • Low Dissolved Oxygen • Supersaturation • High Iron Concentration 2015 Engineering Design & Water Quality Advantages: • Available?? • None Disadvantages: • High / Low Temperatures • Disease!!!! • Pollution! • Too Many! 2015 Engineering Design & Water Quality Designed and treated to safeguard the health of humans, not fish! Advantages • Availability • Reliability Disadvantage • Chlorine • Chloramines • Fluorine • Cost 2015 Engineering Design & Water Quality Parameter Concentration (mg/L) Alkalinity (as CaCO3) 50-300 Ammonia (NH3-N unionized) < 0.0125 (Salmonids) Ammonia (TAN) Cool-water fish < 1.0 Ammonia (TAN) Warm-water fish < 3.0 Carbon Dioxide (CO2) Tolerant Species (tilapia) < 60 Sensitive Species (salmonids) < 20 2015 Engineering Design & Water Quality Parameter Concentration (mg/L) Hardness, Total (as CaCO3) > 100 Iron (Fe) < 0.15 Nitrogen (N2) < 108% total gas pressure < 103 % as nitrogen gas Nitrite (NO2-N) < 1 (0.1 in soft water ) Nitrate (NO3-N) 0 - 400 or higher 2015 Engineering Design & Water Quality Parameter Concentration (mg/L) Oxygen Dissolved (DO) >5 > 90 mm Hg partial pressure Ozone (O3) < 0.005 pH 6.5 - 8.5 Salinity < 0.5 to 1 ppt (Osmotic Regulation) Total dissolved solids (TDS) < 400 Total suspended solids (TSS) < 40 Total Gas Pressure < 103 % (death at ~ 108%) 2015 Engineering Design & Water Quality Critical Parameters • Dissolved Oxygen • Temperature • Ammonia/Nitrite/Nitrate • pH Important Parameters • Alkalinity/Hardness • Salinity • Carbon Dioxide • Solids 2015 Engineering Design & Water Quality Equilibrium Reaction - Ammonia NH4+ + OH - Non-Toxic! NH3 + H2O Toxic! Increase in pH Increase in temperature Note: NH4+-N + NH3-N TAN NH4--N Ammonia - nitrogen 2015 Engineering Design & Water Quality Percent unionized Ammonia-nitrogen Temp. 10ºC 15ºC 20ºC 25ºC 30ºC 6.0 0.1 0.1 6.5 0.1 0.1 0.1 0.2 0.3 pH 7.0 0.2 0.3 0.4 0.6 0.8 7.5 0.6 0.9 1.2 1.8 2.5 8.0 1.8 2.7 3.8 5.4 7.5 9.0 15.7 21.5 28.4 36.3 44.6 2015 Engineering Design & Water Quality Equilibrium Reaction – Nitrite NO2- + H2O HNO2 + OH - Decrease in pH Note: NO2--N Nitrite - nitrogen (mitigated by adding salt (chlorides) 2015 Engineering Design & Water Quality Equilibrium Reaction – Nitrate NO3-N Non-toxic (freshwater systems) Can be Problem in saltwater systems Note: NO3--N Nitrate - nitrogen 2015 Engineering Design & Water Quality pH value expresses the intensity of the acidic or basic characteristic of water. Seawater: 8.0- 8.5 Freshwater: 6.5 – 9.0 Hydroponic systems like pH ~ 5.8 …a challenge for Aquaponics ! 2015 Engineering Design & Water Quality Alkalinity (50 -150 mg/l as Ca CO3) Formula Common Name Equivalent Weight NaOH sodium hydroxide 40 Na2CO3 sodium carbonate 53 NaHCO3 sodium bicarbonate 83 CaCO3 Calcium Carbonate 50 CaO slaked lime 28 Ca(OH) 2 hydrated lime 37 2015 Engineering Design & Water Quality Alkalinity 100 mg/L 100 90 80 CO2, mg/L 70 60 50 40 30 20 10 0 6.50 7.00 7.50 8.00 8.50 pH The relationship between pH, alkalinity, and CO2 concentrations. 2015 Engineering Design & Water Quality Classified as: soft (0-75 mg/L moderately hard (75 – 150 mg/L) hard (150-300 mg/L) very hard (> 300 mg/L) Recommended range: 20 to 300 mg/L CaCO3 2015 Engineering Design & Water Quality • Carbon dioxide is a highly soluble in water. • Concentration in pure water: 0.54 mg/L at 20° C. • Groundwater concentrations range from 0-100 mg/L. Exposure to high carbon dioxide concentrations reduces respiration efficiency and decreases the tolerance to low dissolved oxygen concentrations. 2015 Engineering Design & Water Quality Three categories: • settleable • suspended • fine or dissolved solids “Rule of Thumb” Solids produced by fish : 0.25 to 0.4 kg TSS for every 1 kg of feed fed • upper limit: 25 mg TSS/L • normal operation (species dependent) • 10 mg/L for cold water species • 20 – 30 mg/L for warm water species 2015 Engineering Design & Water Quality Usually reported as parts per thousand, ppt. Osmoregulation “Rule of Thumb” To reduce stress and reduce energy required for osmoregulation, freshwater aquaculture systems are maintained at 2-3 ppt salinity. 2015 Engineering Design & Water Quality Winkler Titration DO Meters – polarographic - galvanic - optical 2015 Engineering Design & Water Quality Dr. James M. Ebeling 18 years – Cornell University Short Course HBOI Short Course Dr. Michael B. Timmons Cornell University Professor 2015 Engineering Design & Water Quality For copy of presentation: JamesEbeling@aol.com 2015 Engineering Design & Water Quality James M. Ebeling, Ph.D. Michael B. Timmons Ph.D. Research Engineer Tucson. AZ J.Thomas Clark Professor of Entrepreneurship & Personal Enterprise Cornell University THE FISH! “Closed Environmental Life Support System for Fish and Plants” OUT Unit Operation (Treatment Process) IN HYDROPONICS • • • RAFT NFT RECIPROCATING 2015 Greenhouse Crop Production & Engineering Design Short Course Advantages of Aquaponics with RAS systems • Dissolved nutrients recovered by plants • Minmizes water exchange rate • Secondary crop – improves profitability Disadvantages of Aquaponics with RAS systems • Large ratio of plants area to fish rearing area • New set of skills –’Green Thumb’ • Limits treatment options for both plants and fish 2015 Greenhouse Crop Production & Engineering Design Short Course Water Based Culture: • • Floating Hydroponic Technique (Raft Culture, Deep water Culture) Nutrient Film Technique (NFT) Media Based Culture: • • • • Reciprocating Systems (Ebb & Flow, Flood & Drain) Dutch Bucket Drip System – Rockwool Slabs Air Based Culture: • • Aeroponics Vertical Gardens 2015 Greenhouse Crop Production & Engineering Design Short Course Hydroponics – Raft System Nelson & Pade, Inc. Friendly Farm Hawaii. Lettuce Factory, Ithaca, NY Tanque Verde High School 2015 Greenhouse Crop Production & Engineering Design Short Course Raft System – Deep water Advantages • • • • • • • Significant buffering due to large volume of water Well adapted for the production of short stature crops pH and EC maintained at constant levels Temperature of root zone optimized Dissolved oxygen maintined with airstones Ease of handling/harvesting Maximized greenhouse floor space Disadvantages • Limited to crops like lettuce/basal/herbs • Plants low to ground 2015 Greenhouse Crop Production & Engineering Design Short Course NFT System Advantages • • • • Low capital start-up costs Ease of handling/harvesting Maximized greenhouse floor space Plants are typically at waist level Disadvantages • Limited buffering due to small volume of water • Difficult to control root temperature • Disruption in water flow leads quickly to dehydration and wilting 2015 Greenhouse Crop Production & Engineering Design Short Course Hydroponics – NFT System Nelson & Pade, Inc. E&T Farms Aquaponics. Aquaculture Systems Tech., LLC Continental Organics 2015 Greenhouse Crop Production & Engineering Design Short Course Reciprocating System (flood and drain or just flood! To ensure adequate aeration of plant roots, gravel beds are operated in a reciprocating (ebb and flow) mode, where the beds are alternately flooded and drained or just flooded. 2015 Greenhouse Crop Production & Engineering Design Short Course Reciprocating System (flood and drain) Advantages • • • • • Lowest capital start-up costs Ease of handling/harvesting Grow a wide variety of crops Maximized greenhouse floor space Media beds at waist level!!!! Disadvantages • Media is or can be very heavy & expensive • Disruption in water flow leads to dehydration and wilting. although not a problem in flooded systems 2015 Greenhouse Crop Production & Engineering Design Short Course Dutch Bucket System (bato buckets) Dutch Bucket is basically a 2.5 to 3 gallon bucket with a special drain fitting that maintains a small reserve of nutrient at the bottom as a precautionary measure. 2015 Greenhouse Crop Production & Engineering Design Short Course Drip System – Rockwool Slabs These cucumbers are being grown in a slabdrip-irrigation system. The nutrient solution is delivered via drip irrigation lines. 2015 Greenhouse Crop Production & Engineering Design Short Course Aeroponics In an aeroponics environment the plants grow with the roots suspended in a misted solution of nutrients. 2015 Greenhouse Crop Production & Engineering Design Short Course Vertical Gardens Tower Gardens In an aeroponics environment the plants grow with the roots suspended in a misted solution of nutrients. 2015 Greenhouse Crop Production & Engineering Design Short Course Perfect Medium • • • • • • Holds a even ratio of air to water Helps to buffer pH changes with time Is easily flushed and re-wets easily after being dehydrated Is reusable or biodegradable Is inexpensive and easy to obtain Lightweight and easy to work with. Sometimes the Perfect Medium is NO medium 2015 Greenhouse Crop Production & Engineering Design Short Course Commonly Used Mediums: Coco Peat Coconut Coir Rockwool Perlite Lightweight Expanded Clay Pellets Common Pea Gravel 2015 Greenhouse Crop Production & Engineering Design Short Course Hydroponics – Raft System Design Crieria: daily feed input/plant growing area (Hydroponics makes up 75% of the system water volume) Raft System: channel (raceway) with a 1 ft depth, usually 4 to 8 ft wide covered by a floating sheet of polystyrene ( 4 ft x 8 ft x 1 to 1 ½ inches) for plant support. "RULE OF THUMB???" 30 to 60 g of fish feed/day m2 of raft area 60 to 90 min water turnover rate Aeration – airstones or diffusers 2015 Greenhouse Crop Production & Engineering Design Short Course Hydroponics – NFT System Design Crieria: daily feed input/plant growing area (Hydroponics makes up small fraction of the system water volume) NFT System: shallow flow of water, 1 lpm with 1% slope "RULE OF THUMB" Waste Treatment 15-40 g of fish feed/day m2 of trough area 1 lpm for rate per 10 ft tray x ~ 4 inch width 1% slope 2015 Greenhouse Crop Production & Engineering Design Short Course Hydroponics – Reciprocating System (flood and drain Design Crieria: daily feed media volume (Hydroponics makes up small fraction of the system water volume) Volume ratio of 1 ft3 of fish-rearing to 2 ft3 of media "RULE OF THUMB" Waste Treatment 1 ft3 of fish fish rearing volume to 2 ft3 of media (1/4 to ½ inch in diameter) 2015 Greenhouse Crop Production & Engineering Design Short Course Design Crieria: daily feed input / plant growing area? Golden Rule of Engineering Mass Balance Production = Consumption + Accumulation Excess or Deficit in Nutrients Plant Growth Nutrients from Fish 2014 Greenhouse Crop Production & Engineering Design Short Course 2015 Greenhouse Crop Production & Engineering Design Short Course Free Macronutrients (90 to 95% dry weight) carbon (C): 30 to 50% oxygen (O): 30 TO 48% hydrogen (H): 6% Macro-nutrients (5 to 10% of dry matter) Micro-nutrients (less than 1% dry weight) chlorine (Cl) iron (Fe) manganese (Mn) boron (B) zinc (Zn) copper (Cu) molybdenum (Mo) nitrogen (N): 22% phosphorus (P): 6% potassium (K): 29% calcium (Ca): 21% magnesium (Mg): 6% sulfur (S): 11% pH Control Calcium hydroxide Potassium hydroxide (Never Baking Soda) 2015 Greenhouse Crop Production & Engineering Design Short Course High pH: Decreases the availability of Iron, Manganese, Boron, Copper, Zinc and Phosphorous Low pH: Decreases the availability of Potassium, Sulphur, Calcium, Magnesium and Phosphorous 2015 Greenhouse Crop Production & Engineering Design Short Course Compromise of Aquaculture and Hydroponics pH: 6.5 to 7.0 • Raise pH – Calcium Hydroxide or Potassium Hydroxide • Lower pH – nitric, phosphoric or acetic acid Temperature: 21 to 23 C ( 70 to 74 F) • Tilapia usually: 25 to 28 C ( 78 to 84 F) • Plants over 23C ( 75F) – slow growth & susceptible to funus and phthium 2015 Greenhouse Crop Production & Engineering Design Short Course Compromise of Aquaculture and Hydroponics Ammonia: < 3.0 • Species dependent • High ammonia concentrations toxic to both plants and fish Dissolved Oxygen: 80% saturation • Tilapia: > 3.0 mg/L • Plants just as important!! Alkalinity: ~ 15 to 30 mg/L as (lowly buffered) CaCO3 • Low levels of CO2 compared to a fish system • Never use Sodium Bicarbonate (Baking Soda), high sodium levels 2015 Greenhouse Crop Production & Engineering Design Short Course Compromise of Aquaculture and Hydroponics Electrical Conductivity: lower than hydroponics systems • • • • Hydroponics: 1500-1800 (µS⋅m−1) Aquaponics: 300 to 800 (µS⋅m−1) Continuous generation of nutrients Organic nature of nutrients results in a lower concentration of salts Common Deficiencies: • Potassium – potasium hydroxide • Calcium – calcium hydroxide • Iron – chelated iron 2015 Greenhouse Crop Production & Engineering Design Short Course Greenhouse Construction Team: Alison Burton, Isaac Hung, Aaron Tirado Agricultural & Biosystems Engineering University of Arizona Design 2015 Greenhouse Crop Production & Engineering Design Short Course Dr. James M. Ebeling 21 years – Cornell University Short Course June 23-25, 2015. Newburgh, New York Dr. Michael B. Timmons Cornell University Professor 2015 Greenhouse Crop Production & Engineering Design Short Course