Marine Hatchery Water Conditioning Module

Final Report

Sablefish Canada Inc

AIMAP 2011-P07

Executive Summary

Sablefish Canada received $200,000 in AIMAP funding to build a Marine Hatchery Water Conditioning Module (MHWCM)for the purpose of controlling temperature and salinity of hatchery culture water, recovering waste heat generated by the chiller, and recycling used incubation water. Slight fluctuations in temperature and salinity from optimal conditions are known to cause deformities and mortalities in juvenile marine fish. The goal of this project was to design and test a system that reduced deformities by 50% by providing the optimal culture environment and utilizing energy efficient technologies.

In this innovative project, Sablefish Canada constructed and implemented the MHWCM that creates the precise temperature and salinity conditions required to meet marine fish culture requirements. The MHWCM innovative equipment delivers water of various salinity levels and temperatures, 24 hours a day seven days a week with 100% reliability. This innovative technology has good potential to become the industry standard for all new marine fish farms.

The development of the MHWCM has created an opportunity for Canadian aquaculture to increase its competitiveness in the world market and to market cutting edge technology globally. The marine hatchery industry is too small for manufacturers to produce specialized equipment so Sablefish Canada anticipates that the MHWCMwill meet this market niche.

Introduction

Sablefish Canada Inc is a pioneering British Columbia aquaculture company committed to sustainable environmental practices and community-based economic development. As Canada emerges from the global recession, high value aquaculture exports like sablefish are well positioned to form part of Canada's new economy. Aquaculture is a rapidly growing global industry and Canada is in a unique position to dramatically increase its current $1 billion share of the $35 billion world aquaculture market. Sablefish aquaculture production in Canada could exceed 100 million pounds a year or $600 million in the next 20 to 30 years.Over the past six years, Sablefish Canada has invested $12.78 million and conducted the pioneering research and development necessary to establish a commercially viable sablefish industry in Canada.

Atlantic cod, sablefish, sea bream, and sea bass juveniles have deformity rates of 15% to 26%. It is known that temperature and/or salinity play key roles in the rate of deformity and mortality in marine fish hatcheries. Research published in November 2009 by the Norwegian Institute of Food, Fisheries and Aquatic Research (Nofima), shows great promise for reducing the rate of malformations in farmed cod and other species by using precise temperature and flow control in the larval stage. Also Nofima project scientists concluded that “Cod Fish without malformations provide better earnings for the cod industry” in recognition that deformed fish that survive grow slower and yield a discounted market price. Sablefish Canada conducted a worldwide search for an equipment package that could meet the specification of the MHWCM and none were found that were appropriate to meet production requirements, reliability, and energy efficiency.

An additional challenge for marine fish hatcheries is that the equipment must be able to deliver water of various salinity levels and temperatures 24 hours a day seven days a week to the brood stock, incubation and larva sections of the hatchery with 100% reliability.

Methods and Solutions

Published and non-published information on salinity modulation, high efficiency chillers, and environmental control computers was sourced and used to determine the best individual components of the MHWCM.

MHWCM Design and Function

A Norwegian Hycool energy efficient chiller was modified to work with seawater. Chilling the hatchery seawater intake was accomplished by running the water through a 66 HP high efficiency, Hycool unit that chills 150 GPM of intake water by 7°C. The Hycool chilling unit, which had never before been used in North America, is 52% more efficient than the conventional North American Freon chillers because Hycool uses potassium brine with outstanding thermodynamic properties. In order for the Hycool chiller to be used with seawater, it was modified by adding titanium heat exchanger tubing. The 66 HP Hycool chillers consume $30,020 a year in electricity to operate, superseding the current Freon units that consume $58,750 annually in electricity, thus minimizing both capital and operating costs.

A chiller heat recovery unit harveststhe waste heat energy produced by the Hycool compressors and uses it to preheat the boiler intake water by 7°C. All marine fish hatcheries produce live feed (rotifers and artemia) to feed their larvae, which requires warm water previously produced from the 400,000 BTU atmospheric boiler at an operational cost of $3,714 per month. The waste heat recovered from the four compressors of the Hycool chiller was enough to replace heat formerly provided by the boiler. Actual decrease in heating costs will be evaluated but is expected to be up to $33,000 annually, exhausting 150 tons less carbon into the atmosphere.

An Israeli ODIS desalination machine was custom engineered to remove the required amount of fresh water from the intake seawater to meet the specified salinity requirements. This was accomplished by replacing the 370 PSI pump on the reverse osmosis machines with a variable pressure pump controlled by an upstream salinity sensor. If the hatchery salinity is reduced such as after a rain storm, the pump pressure increases and forces more fresh water out of the intake water to produce the correct water salinity. If the incoming seawater salinity is higher, the pressure reduces and less fresh water is removed and the output salinity remains constant. The salinity booster eliminates the need to purchase salt to create high salinity water and prevents the unintentional introduction of unwanted sulphur loving bacteria that come with the purchased salt and have to be removed to prevent contamination. The machines were constructed in two shipping containers and were engineered to “plug and play” into the hatchery electrical and plumbing systems.

Versatile Construction engineered and fabricated a 2600 watt UV system that was installed on the recirculation system in the broodstock building. 

A new Argus environmental control computer module was installed tosynchronize and maximize the efficiency of the MHWCM. Since 2007, Sablefish Canada has coordinated its hatchery using Argus, a computer control system used by the NASA space program. The Argus control system is modular so that new modules can be added and tied into the existing ten modules at the hatchery as required and provides online monitoring of all chiller components by refrigeration engineers in Europe should the system have any operating issues.

Key activities for the construction and commissioning of the MHWCM were as follows:

• Confirmed all equipment design specifications and engineering calculations;
• Researched, ordered, and procured the correct equipment, including chiller; desalination machine; UV sterilization unit; and environmental computer; and arranged to have it delivered to the site;
• Prepared the site for the arrival of the equipment, this included pouring a cement pad and putting the necessary wiring and plumbing in place;
• Received, assembled and installed the equipment on site;
• Tested all components of the equipment; and
• Commissioned the MHWCM to run 24 hours a day, 7 days a week, and coordinated equipment to provide maximum efficiencies.

Results

The new MHWCM functions as designed providing salinity and temperature control and the hatchery manager can now dial in the precise temperature and salinity water parameters required to meet the juvenile sablefish requirements. The module recycles the high salinity incubation water and extracts the heat from chillers for preheating the live feed water. Also the high salinity water is produced onsite eliminating the need to purchase truckloads of salt thus reducing costs and electrical demand.

Reduction in Deformities

Evaluation of deformities is ongoing however early indications are that the MHWCM will meet the target goal of reducing deformities by 50%. A preliminary evaluation has been completed between Year Classes 2010 and 2011. Year Class 2010 larvae were reared on lower salinity and variable temperature of the ambient incoming water and Year Class 2011 larvae were reared on controlled high salinity and low temperatures achieved with the MHWCM. 

Reduction in Bacteria

As a result of installing the UV equipment, there has been a significant reduction in saltwater bacterial colony counts in broodstock water. This has been verified by Pfizer during testing for presence of saltwater bacteria.

Though newly installed, the benefits of this innovated system are apparent and in addition to producing more viable juveniles and reducing bacterial culture counts in broodstock water, the new MHWCM technology reduces costs and energy requirements.

Future Activities

The installed MHWCM will be tested for at least six months to evaluate full functionality and cost savings. It is expected that over this time all the following targets will be met or exceeded: 

• Reduction of spinal deformed fish by 50% (from 20% to 10%);
• Reduction of salt purchases from $50,000 to zero;
• Reduction of energy consumption by $110,780 year;
• Marine Hatchery Water Conditioning Modules will be marketed to marine hatcheries around the world – see marketing section below; and
• A final report on the scientific achievements, energy efficiencies and cost savings of the project will be prepared for public dissemination – see marketing section below.

Marketing

The development of the MHWCMcreates an opportunity for Canadian aquaculture to increase its competitiveness in the world market and to market cutting edge technology globally. The marine hatchery industry is too small for manufacturers to produce specialized equipment so Sablefish Canada anticipates that the MHWCM will meet this market niche.

Canada's flagship breeding marine fish hatchery is a showcase for carbon neutral, sustainable aquaculture using cutting edge technology that Canada can export globally. Transferable technology will benefit local and worldwide marine hatcheries by reducing the percentage of uneconomical, deformed fish farm crops by up to 50% and concurrently reducing energy consumption and carbon emissions.

Strategy for marketing the MHWCM to marine hatcheries globally:

• Development of information materials describing the project and water conditioning module and the benefits of the system.
• Tokyo International Fisheries and Technology Expo July 18-20, 2012.
  • Project and water conditioning module brochure will be developed and translated.
  • Sablefish Canada has rented a booth as a home base for promotion of the technology.
  • Selected individuals have been contacted and invited to meet for further discussion such as government representatives of the Miyagi Prefectural Cold Water Marine Research Centre and representatives of the Owasebussan Co. Ltd. (fish farm).
• Aquaculture Canada 2013, Guelph, ON
  • Presentation of project and water conditioning modules including results of six months testing for reduction in costs due to not having to use salt, reduction of energy consumption, and improvement in fish quality (reduction in deformities).
• AQUA NOR 2012-2013 Trondheim, Norway
  • Presentation to potential buyers at the largest Aquaculture trade show in the world.
• Tours organized for interested groups at the hatchery, including potential purchasers of identified (Marine Farms ASA, Codfarmers ASA, Salmar ASA, Cod Hatcheries in Norway, Scotia Halibut Ltd. in Canada and Trout Lodge in the USA).
• A final report on the scientific achievements, energy efficiencies, and cost savings of the project will be prepared for public dissemination.
• The benefits of the MHWCM innovation will be communicated to the Marine Aquaculture industry at large through the newsletters and online communications instruments of the Canadian Aquaculture Industry Alliance.

Conclusion

The AIMAP funding has supported the MHWCM technology innovation thus enabling the development of sophisticated environmental control required for all successful marine finfish hatcheries and the sustainability of the marine fish culture industry in Canada. This new technology will improve the quality, supply, and market value at slaughter for both warm and cold water finfish species.

Though newly installed, the benefits of this innovated system are apparent, and in addition to producing more viable juveniles and reducing bacterial culture counts in broodstock water, the new MHWCM technology will eliminate the need to purchase salt, and will reduce energy costs.