Nanaimo Land-Based Steelhead Model Aquafarm

Final Report
Taste of BC Aquafarms Inc
AIMAP 2012-P18

Introduction

A number of government agencies and task forces looked at the freshwater aquaculture sector across Canada and found that the sector is performing far below the opportunity and potential that exists for freshwater aquaculture development in Canada. Despite many inherent advantages and opportunities growth has been forestalled, and in some regions of the country including British Columbia, the industry is in decline.

Taste of BC Aquafarms is a venture that was spawned through the Freshwater Aquaculture Action plan of the Inter‐Provincial Partnership for Sustainable Freshwater Aquaculture Development (IPSFAD). This Action Plan was intended to focus applied research, research and commercialization efforts on those issues that could best enhance productivity and profitability within the freshwater aquaculture sector in Canada. A key finding of the action plan was that there was a need in Canada to establish one or more freshwater aqua farms that would serve as models for the environmentally and economically viable expansion of freshwater aquaculture in Canada. It has been recognized by Canada and foreign jurisdictions that the development of model farms which suit local needs are the best way to commence the establishment of freshwater aquaculture industries.

The anticipated outcome of Taste of BC Aquafarms is a model for a ‘turn‐key' freshwater aquaculture operation that will help catalyze the development of a sustainable freshwater aquaculture industry in British Columbia and across Canada. The model farm will assemble and apply technology and research necessary for commercial needs, incorporating the need for environmental sustainability as well as economic viability. Under the terms of reference developed by the IPSFAD program, to qualify as a model farm the facility must be industry‐driven: (1) be profitable; (2) be environmentally sustainable; (3) uphold fish welfare requirements; (4) facilitate industry expansion; (5) earn social licence from consumers and other stakeholders; and (6) support effective communications.

Steve and Janet Atkinson, owners of Taste of BC Aquafarms took up the challenge for the development of the model farm in British Columbia. Their goal was to transform their low tech, low producing, trout and sturgeon farm into an efficient state‐of‐ the‐art commercially viable production aquafarm. In 2012, they assembled a broad based team of stakeholders and partners and submitted a proposal for funding under Department of Fisheries and Ocean's Aquaculture Innovation and Market Access Program (AIMAP).

This final report will conclude a successful AIMAP project under the 2012/2013 program. This project has been brought to a close with fairly close adherence to the projections of the project submission. Some unavoidable delays were experienced and slight adjustment to budget figures on individual items, with the overall project largely on time and on budget. The AIMAP portion of this project has come to a successful completion, but the model farm project will continue. Taste of BC has committed to collect data as to the performance of the farm, over the next two years at a minimum. This data will be compiled into a clear concise format that will allow for easy evaluation of the performance metrics of this farm. Taste of BC has committed to make the information gathered freely available.

Phase One

Project Deliverable 1 (i) (ii) (iii) – Engineered Plans in Place, Ready to Start System Construction, Licences in Place.

June 8, 2012 marked the start of the project. Since the farm was fully licensed and no further permits were required the project was able to begin without delay. Site clearing grading and preparation commenced immediately. The site preparation proved to be considerably greater than what was expected. The entire footprint of the model farm had to be excavated to a depth of approximately ten feet. This was required due to the high water table. The site was then reconstructed using a variety of sizes of rock, drain rock and fill. Detailed design drawings were commissioned and 30% complete drawing set was delivered to Taste of BC on July 17.

Project Deliverable 2 (1) – Treatment Vessel meets PRAqua field inspection requirements.

Construction of the treatment cell began upon completion of the site works. Engineered drawings were prepared and construction began September 17, with completion October 25. The engineering of the treatment cell was a process in itself. Vessels such as these are unusual and extreme cost overruns have been the norm for comparable projects. Taste of BC was able to hold their costs in line for this element of the project. The treatment vessel for this farm is a significant innovative advancement being applied in this farm. Fluidized Sand Bio Reactors have been known as a superior mode of treatment in RAS facilities for decades; however the design has led to them being significant “power hogs.” The more technical Moving Bed Bio Reactors have been perceived as a more efficient mode in regard to use of electricity due to the reduced resistance of the lighter media used in the MBBR systems. In this farm the FSB has been submerged from the system and is fed by gravity. It is expected that this new design will reduce pumping costs by at least 25% making it not only more efficient as a bioreactor but also as to use of electricity.

Project Deliverable 2 (ii) – Culture Tank installation and under grade piping meets PR Aqua field inspection requirements.

Also in October plumbers began setting layout for the culture tanks and system plumbing. Construction of the system began with the laying of the main supply piping. The first foundation for the culture tanks began construction November 28. Tanks assembly followed with the last tank placed March 12, 2013.

PRAqua consulted regularly and visited the site throughout the construction process insuring that installation met the design criteria. Steve Atkinson of Taste of BC has acted as General Contractor for the project.

Project Deliverable 2 (iii) Building foundations in place.

In October the construction of the foundation commenced. In the original AIMAP proposal Taste of BC contemplated building a “greenhouse” structure to house the project. With the final design parameters embracing a larger size of fish for harvest the layout of the farm had to be changed. This change led to a footprint that could not be accommodated by a greenhouse. A fabric covered building 204' x 70' was decided upon as the building solution for the project. The foundation was formed and poured in three separate stages. In November the first stage encompassing the West, North and 2/3 of the East walls were poured. On January 15 the remainder of the East wall was completed at the time of the construction of the LHO and header tank. The final wall was poured in March when most of the construction inside the building was complete. The building was completed on April 25, 2013

Project Deliverable 3 (i) Installation of equipment meet PR Aqua field inspection requirements.

Construction and installation of the tanks, treatment cells, LHO and Header tank, and all plumbing commenced in October 2012. PRAqua design team and engineers visited the site regularly and monitored the construction insuring the design criteria were met.

Project Deliverable 3 (ii) Construction punch list completed functional testing parameters met.

At the end of the 2012‐2013 fiscal year the total system was not complete. Construction was approximately 95% complete with only the purge cells operational. The purge cell was tested by PRAqua with necessary adjustments completed. Since that time construction continued and was
essentially completed in early June. On June 8 the full system was turned on and commissioning of the various components began. Fish were moved into the culture tanks and emphasis switched from construction to husbandry.

Project Deliverable 3 (iii) Report comparing to industry and research standards e.g. Davidson and Summerfelt 2004

This farm embraces the innovation of using dual drain circular tanks as proposed by Davidson and Summerfelt. A number of design changes have been made in the dual drain system of this farm that is meant to address challenges reported in this technology. The side boxes have been completely reworked to avoid problems that have been reported by others. Since the farm is not fully commissioned it is not possible yet to report completely on the efficacy of these changes. Some of the tanks now have fish stocked in them. They are self cleaning and it appears that the new side box design has eliminated the “air lock” problems some have experienced with the dual drains. In subsequent PMM reports that will be generated this will be fully discussed.

A major innovation of this farm, in comparison to previous applications of the RAS technology employed is the below grade construction of the fluidised sand bed biofilter treatment vessels. In previous applications the treatment cells have been installed completely above grade. Pumping to them has been a major operating cost of the farms that employ this technology. Operating costs in the model farm will be greatly reduced by pumping to an unobstructed header tank and then flowing the water to the biofilter by gravity. This alone should reduce electrical consumption of the farm by at least 25 percent. Additionally this new design allows for a split of the process flow, diverting approximately 50 percent of the flow through the treatment cell allowing for maximum efficiency of this component of the farm. It is commonly agreed that fluidized sand bed filtration is the most effective mode of treatment of wastes in a fish farm. The high cost of operating these in past applications has led the industry away from them to less reliable and less efficient bioreactors which have been more cost efficient to operate. With the changes made in this farm we are able to reduce capital costs associated with biofiltration as well as operating cost while improving reliability and efficiency.

Project Deliverable 3 (iv) Staff demonstrate competence with facility operation.

Fish were first stocked into the purge cell component of the system on March 28 2013. Staff are learning the system and will continue to do so as the various components are brought fully on stream. It will take approximately one year to reach a steady state of production in the farm. Since fish have been moved into the main culture system no failures have been experienced and the fish stocked are performing well.

Phase Two

Project Deliverable 4 – Fish on Site. Performance Monitoring begun on all indicators

On March 28, 2013 25,000 30 g fish were stocked into the system. These fish were stocked in the “purge” cells that are partial RAS and independent of the main system. An additional 7,500 800 g fish were also stocked on the same date. Holding these fish in the purge cells proved to be problematic.

Delays in servicing the farm with electricity and a change from three phase to single phase power led to delays in starting up the main system. Without filtration in the purge cells it was not possible to keep water quality at optimum levels. The larger fish experienced an outbreak of a gill parasite leading to significant mortalities. The tank holding the smaller fish experienced a blocked drain overnight leading to low dissolved oxygen levels and mortalities. An additional 15,000 20 g fish were received and were being held in the old flow through system of the farm. These were moved into the main recirculation system on June 8. There are now approximately 30,000 fingerlings in three cohorts stocked into the system. The PMM has begun to the degree it can be while waiting the completion of the installation of the monitoring equipment. With the assistance of NRC –IRAP two student interns have been hired. One will conduct the Performance Monitoring Program and the other will be responsible for general fish husbandry.

The main instrumentation panel for the farm includes advanced systems monitoring and data logging capacity. Among the parameters to be measured and recorded by the system are:

• Dissolved oxygen (4 stations – tank effluent; biofilter inlet, biofilter effluent; tank inlet)
• Temperature (4 stations ‐ source water, system water, inside air, outside air)
• pH (2 stations ‐ tank effluent; tank inlet)
• Carbon dioxide (2 stations ‐ tank effluent; tank inlet)
• Reduction – Oxidation Potential – ORP (1 station ‐ ozone control with back‐up)
• Electrical energy consumption (water pumps, oxygen generation, CO2 stripping, drum filtration and backwashing)

The sampling frame for the environmental monitoring program has been designed to include the influent (new water source), process water from pre‐ and post‐treatment locations, overflow water discharged to the environment and the solid waste stream discharged from the drum filter backwash to the geotextile dewatering bag.

Metabolic Wastes

Parameters of concern for routine analysis in the water include: Total Suspended Solids (TSS), total phosphorus (TP), soluble phosphorus (PO4), total ammonia nitrogen (TAN), nitrite (NO2), nitrate (NO3), biochemical oxygen demand (BOD5) and carbon dioxide (CO2). With the exception of NH3 and CO2, water samples are now collected on a weekly basis and submitted for analysis of the above parameters from the following locations:

• tank effluent immediately before the drum filter;
• biofilters influent;
• Biofilter effluent; and
• Return flow to tanks.

Sampling of the drum filter backwash is not required as upstream and downstream sample results can be used to conduct a mass balance on the proportion of wastes removed in the backwash.

Samples collected immediately before the drum filter would represent the “worse case” conditions with respect to water quality within the rearing units. Samples collected immediately after the LHO represent both the treated water supply for the rearing unit as well as the overflow discharged to the environment.

Methodology
Three auto‐samplers are employed to collect water samples at the above locations (Hach / American Sigma 900SD Refrigerated Sampler, Can‐Am Instruments Ltd., Oakville, ON). As flows are constant within the rearing unit, samples are being collected automatically as timed composites during a 24‐hour period (one 24‐hour period per week). At the end of the 24‐hour sampling period, the collected sample is transferred to clean jars supplied by the contract laboratory, refrigerated, and submitted for analyses. Once per month, coinciding with a weekly 24‐hour sampling event, a grab sample from the ground water supply is also collected for analysis.

Laboratory Analyses
The services of North Island Labs, a CAEAL (Canadian Association of Environmental Analytical Laboratories) accredited laboratory has been retained to conduct water quality analyses.

In-Situ Monitoring

Monitoring of ambient water quality parameters is being done using meters with data logging capability. Parameters monitored include dissolved oxygen (DO), temperature, pH, carbon dioxide and ammonia. To monitor and record DO, pH and temperature on a continuous basis, a sonde is installed immediately upstream of the drum filter inlet, with a second sonde deployed in the return flow to the fish tanks. These units measure the parameters pre‐ and post‐ treatment, as well as the water quality discharged at the overflow to the environment.

Ammonia monitoring with daily measurements are being taken. The portable unit allows additional sampling within the rearing units and pre‐ / post‐ biofiltration to monitoring treatment efficiency. All sampling results are being recorded in a database. A portable CO2 analyzer is installed in the drum filter discharge sump, upstream of the biofilters. A second unit is installed in the return flow to the fish tanks. Data from continuous monitoring will be collected automatically be a data logger and posted to the database.

Pathogens & Chemicals

Due to the nature of recirculating systems, only limited use of therapeutants and disinfectants is expected. To protect the viability of the biofilter, Standard Operating Procedures (SOPs) are required for use of common federally‐approved treatment agents. Formalin, Chloramine‐T and other commonly used agents may be applied in bath treatments. Formalin‐based products, which are most‐commonly used, are applied in a diluted state and are highly volatile, making their measurement in water impractical. When used, therapeutic agents are normally applied under veterinary supervision, sometimes as a medicated feed for ingestion by the fish. Any unusual disease outbreaks would require specialized veterinary interventions and prescription of appropriate medications. This farm is committed to not use antibiotics or other chemical therapeutants. However protocols will be established in the case of extraordinary circumstances that force the use of treatment protocols.

Solid Wastes

Solids from a sampling from the drum filter backwash will be sampled monthly for characterization of solids wastes from the model farm. Grab samples would be placed into plastic bottles supplied by the contract laboratory, refrigerated and submitted for analysis of total phosphorus (TP) and total nitrogen nitrogen, ammonia, nitrate and nitrite. In addition, periodic analysis of total metals by ICPMS is proposed (4 times / year).

The farm has experienced two mortality events. As mentioned previously fish were stocked into the purge cells of the farm as a temporary measure. It was necessary to order fingerlings early in the construction stage to insure availability when they were needed. Delays in construction led to the need to make temporary accommodations. Further delays due to a change in electrical service of the farm due to the utility company making changes led to holding these fish for much longer than expected in less than optimal conditions. This led to mortalities. Since moving the fish into the RAS system mortalities have remained below 1% and the fish are growing as anticipated in the bioplan.

Phase Three

Project Deliverable 6 – Construction Completed, functional testing parameters met. Construction budget compared to actual.

At the conclusion of fiscal year 2012/2013 this project was approximately 95% complete. Delays beyond the control of the proponents have pushed completion back by approximately 8 weeks from the target date. The budget for this project was $1,298,109, the actual cost of construction has been $1,460,176.

The construction of the farm has proceeded largely to projections both in time and cost. The cost overruns can largely be attributed to the increased scope of the site works, the larger more expensive building housing the farm and increased electrical expense. Delays can primarily be attributed to three factors. The final contribution agreement under the AIMAP program was not executed until late June. This pushed back the start of the project from April as was contemplated in the proposal. The second issue that led to delay was the increased scope of site works.

The third issue was due to problems with electrical service to the farm site. Taste of BC has had discussions with BC Hydro regarding this project for at least two years. There was concern raised on the part of BC Hydro that the electrical grid in the area of the farm was under stress and that the increased load would present problems for BC Hydro. Taste of BC was asked to design for 3 phase power as BC Hydro was planning a system upgrade. When electrical service was called for BC Hydro informed Taste of BC that there would be a cost of approximately $75,000 to service the site with 3 phase power. Since the project could not bear the significant additional cost the project was delayed while a solution was found. In the end it was decided to redesign and reorder components to allow for electrical service to be single phase. Some additional costs resulted due to the switch.

In the end the projected completion was delayed by approximately two months. However, the actual length of the project remained at very near the initial projection of 11 months.

Project Deliverable 7 ‐ Diary of all site visitors

The farm has enjoyed visitors from around the world – China, Japan, Chile, as well as numerous North American visitors. In addition several presentations of the project have been made to community groups and others interested in the development of Freshwater Aquaculture.

Project Deliverable 8 – First interim PMM report complete. Progress report toAIMAP

The first PMM report has not been completed due to the delays in start up of the project. Data has begun to be accumulated. Canadian Aquaculture Systems Ltd. has been commissioned to collate and interpret the data into a concise report. A data base has been designed for the assembly of the data and the information gathered is being entered into the database. Taste of BC commits to provide these reports to DFO over the next two years.

Strategic Partnerships

At the outset of this project Taste of BC assembled a varied team of interested parties and “partners” who would help the model farm become a significant resource for the development of freshwater aquaculture in British Columbia and in Canada. PRAqua, the designer and principal supplier for equipment of the farm, donated their engineering as an in‐kind contribution to the project. This relationship is expected to continue with PRAqua using the farm as a R&D site. The close proximity of the farm to the PRAqua offices has already proven to be valuable to both Taste of BC and PRAqua.

The involvement of Vancouver Island University and the faculty of Fisheries and Aquaculture benefit the students, Taste of BC and the industry as a whole. Students have already begun to complete Practicum courses at the farm. Student Interns have been hired to conduct the Performance Monitoring program as well as general husbandry on the farm. Taste of BC has entered into an agreement to share a Post Doctoral researcher starting in May 2013.

It is expected that the model farm will provide a unique training ground for the fisheries and aquaculture students exposing them to a fully monitored real world production farm. Taste of BC will likewise benefit from the expertise of the VIU faculty and staff as well as providing a home for the redundant remnant of fish provided through the academic program of the university. The model farm was initially a vision of the Interprovincial Partnership for Freshwater Aquaculture Development. The monitoring methodologies have been developed using the guidelines set out by IPFSAD. Taste of BC is committed to providing the data set gathered at the model farm for at least two years. In cooperation with IPFSAD, Taste of BC will produce a blueprint for the development of a family farm sized aquaculture operation. This information will be available to the public domain.

A number of other groups have expressed interest in utilizing the model farm as a living laboratory for a variety of projects pertaining to aquaculture development. A major aquaculture pharmaceutical company is planning a research project tracking the development of the biofilter. A number of equipment suppliers have expressed interest in conducting R&D on new products at the farm. Taste of BC is committed to make the model farm available to the industry to conduct ongoing research and development wherever practical. We believe that the Model Steelhead Aquafarm will become a valuable asset to the Canadian aquaculture industry, firstly by providing a data set that will help document an understanding Recirculating Aquaculture Systems and secondly by providing a venue that will allow for the further development of innovation that will make the sector successful.

Communication/ Industry Engagement

A significant part of the model farm project is to build awareness of the RAS freshwater aquaculture industry, to communicate the success and difficulties of this project and to help build confidence in freshwater aquaculture as a sustainable, financially viable, and investable business. To that end Taste of BC has expended significant effort to engage stakeholders at each level of the development of this farm. We have attended industry meetings and conferences, hosted various delegations and made several presentations of the development of the farm to industry groups and conferences. Taste of BC has been involved in each of the Aquaculture Innovation Workshops which have been hosted by Tides Canada and has made presentations detailing the development of this farm. To date more than 250 individuals have toured the farm. These have come from many countries, including: China, Japan, Ecuador, Chile, Norway, Denmark, Germany, USA, Russia, and Turkey and from across Canada. These represent aqua culturists, persons interested in investing in aquaculture, aquaculture design / supply firms, scientists and researchers, academics, financial services providers, seafood distributors and end users as well as many other groups.

Conclusion

The Nanaimo Land Based Steelhead Model Aquafarm project is now well underway. Taste of BC Aquafarms Inc is very appreciative of the many that have helped in bringing the construction phase of this project to a successful completion. The AIMAP contribution to this project was essential. Without the AIMAP program this project would not have been possible. Conclusion of this phase however, does not mark the end of this project. Rather, it simply allows the project to start.

In order for freshwater aquaculture to flourish in British Columbia and in Canada it is important that a successful model be developed that will validate the industry as viable. It must prove to be sustainable, environmentally responsible and economically viable. Data that verifies this needs to be gathered and made available to proponents, financial services providers as well as to regulators and the public at large. Taste of BC has experienced the great difficulty in raising capital for a venture such as this due to the lack of a verifiable successful model. Over the next two years we will verify and document all aspects of the operation of this model farm. That data will be freely shared. Already prospective aqua culturists have been drawing on the experience of the construction of the model farm to help guide them in investing in this industry. It is our hope that our success will lead to a significant growth in the freshwater aquaculture sector in Canada over the next few years.

Addenda:

One unique aspect of the project is the team that has joined with the Atkinson's in this project. PRAqua is a leader in the design and technology of Recirculation Aquaculture Systems worldwide, and is located in Nanaimo not far from the farm site. PRAqua has donated their design and engineering services valued at over $130,000 to the project. In the long term PRAqua will have access to the farm for R&D purposes and Taste of BC will benefit from their ongoing involvement in the operation of the farm. Vancouver Island University's Fisheries and Aquaculture Department, along with the International Center for Sturgeon Studies and the Center for Shellfish Research will also partner with Taste of BC. The farm will host practicum students, be available to students and faculty for research and teaching purposes, as well as provide excess fish generated through the educational programs of the university.

Taste of BC has also committed to working with IPFSAD in the Performance Monitoring and Measurement of every aspect of the operation of the farm for at least two years. This data will be collated and published and made available to the public domain. It is anticipated that this data set will lead to a blueprint for the development of a family farm size model aqua farm that could be duplicated “turn key”, aiding the growth of the freshwater aquaculture sector.

A number of other parties, including major feed producers and aquatic animal laboratories, have expressed interest in conducting ongoing research projects relating to a number of aspects of the operation of recirculation aquaculture technologies (RAS). Taste of BC is committed to working with each of these and truly making the model farm a site for R&D aiding RAS development in Canada.