Source: J M MALONE & SON INC submitted to NRP
MODIFIED PARTITIONED AQUACULTURE SYSTEM (P.A.S.) TO PRODUCE HIGH VALUE FISH FOR HUMAN CONSUMPTION.
Sponsoring Institution
National Institute of Food and Agriculture
Project Status
COMPLETE
Funding Source
SMALL BUSINESS GRANT
Reporting Frequency
Annual
Accession No.
1006194
Grant No.
2015-33610-23534
Cumulative Award Amt.
$100,000.00
Proposal No.
2015-00483
Multistate No.
(N/A)
Project Start Date
Jun 1, 2015
Project End Date
Jan 31, 2017
Grant Year
2015
Program Code
[8.7]- Aquaculture
Recipient Organization
J M MALONE & SON INC
1156 MALONE LK
LONOKE,AR 72086
Performing Department
(N/A)
Non Technical Summary
Competition from foreign countries has driven down the price paid for catfish forcing many domestic catfish farmers to leave the business of seek alternative species of fish to produce. There is a great interest among such fish farmers in producing high value species such as bass, sunfish and crappie for human consumption. However, these high value species have behaviorial characteristics that makes producing them in conventional open ponds unprofitable. In-pond confiment systems such as the partitioned aquaculture syste (P.A.S.) developed for catfish production can produce high yeilds of fish and overcome the behavioral issues related to these species. Because such high value species require better water quality than catfish and higher feed protein levels, modifications must be made to in-pond confinements to improve solid waste removal and nitrogenous waste processing.A prototype in-pond tank was designed and built by J.M. Malone and Son, Inc. Solid waste collection and processing apparatus installed on the prototype will be evaluated to determine their cost benefit relative to improved water quality. Replicated tank studies will be conducted to test the effect of three levels of solid waste removal and processing apparatus on water quality. Appropriate modifications to the prototype design will be designed and fabricated. A protocol for construction of a commercial system will be drafted and a cost analysis will be performed.
Animal Health Component
33%
Research Effort Categories
Basic
33%
Applied
33%
Developmental
34%
Classification

Knowledge Area (KA)Subject of Investigation (SOI)Field of Science (FOS)Percent
40202102020100%
Knowledge Area
402 - Engineering Systems and Equipment;

Subject Of Investigation
0210 - Water resources;

Field Of Science
2020 - Engineering;
Goals / Objectives
Fish confinement systems such as the (P.A.S.) developed for catfish would allow the better management of high value species (HVS) and increase production and profitability. However, HVS require considerably better water quality than catfish. Therefore, any in-pond confinement based production system used to produce HVS requires modification to improve solids removal and to process increased nitrogen inputs resulting from the feeding of required higher protein feeds. J.M. Malone and Son, Inc. has designed, built and successfully raised HVS in a prototype system which has demonstrated rapid solid waste removal and improved survival, production and profitability of HVS. The goal of this research is to determine the cost benefit of additional solids capture and processing within the system and to finalize the design and manufacture of the system prior to commercialization. The objectives of this research are to: 1) Evaluate a radial flow separator installed on the existing prototype and characterize the solid waste collected; 2) Evaluate a sequencing batch reactor installed on the existing prototype and quantify it's capacity to process nitrogenous wastes; 3) Conduct tank trials to determine the effect of solid waste collection and processing on the algal reactor and 4) Determine and fabricate appropriate modifications for a second generation in-pond tank prototype and evaluate manufacturing methods, materials and costs.
Project Methods
Sixty day old, 2 inch feed trained LMB fingerlings produced on our facility will be stocked into the existing modified 1/10 acre P.A.S. (prototype in-pond tank , Objective 1 and 2) and the tank trial LMB tanks (Objective 3) on June 1, 2015 and reared for 120 days. The modified P.A.S. (prototype in-pond tank) will be stocked with 25,000 LMB and each tank trial LMB tank will be stocked with 500 LMB. The LMB in the modified P.A.S. (prototype in-pond tank) will be fed a 48% protein ration multiple times daily via an automated feeder according to a proprietary feeding chart. LMB in the tank trial LMB tanks will be fed by hand twice daily according to the same feed chart. Objective 1) Throughout the production period water samples will be collected daily at a standardized time from the: a) tank influent b) sidewall tank effluent c) tank d) center drain tank effluent/radial flow separator influen e) radial flow separator effluent. Total suspended solid (TSS) levels will be quantified and characterized using the method described by Pfeiffer et al. (2008) and Standard Method 2540-D (APHA, 1995). The sieves used for the determination of TSS will be custom-made using Nytex woven screen mesh attached to the bottom of a section of PVC pipe (schedule 40, 4" diameter). As described by Pfeiffer et al. (2008), a 10 gallon water sample will be serially filtered through the sieves with mesh sizes of 500, 250, 105, 55, and 23 µm. The collected solids on each sieve mesh will be rinsed off with distilled water, which will be filtered using glass fiber filters (Whatman, GF/C, 1 µm pore size). Each glass filter will be oven dried (103-105 °C), and TSS will be calculated from the difference in dry weight of each glass fiber filter before and after filtering the sample. The depth of solid waste collected in the radial flow separator will also be measured and recorded weekly. Using the TSS fraction data, changes in TSS concentrations through the system components will be characterized, and the effectiveness of the radial flow separator in the removal of solids from the center drain waste stream will be assessed.Objective 2) Solid waste will be drawn from the radial flow separator and pumped into the elevated S.B.R once daily. The S.B.R. will be operated using a 2 minute fill, 6 hour anoxic react, 6 hour oxic react, 6 hour anoxic react, 5 hour oxic react, 8 minute settle, 50 minute decant cycle. Supernatant from the S.B.R. will gravity flow back into the algal reactor via a solenoid valve. Water samples will be collected daily at a regular time from the inflow to the S.B.R., effluent from the S.B.R. and the algal reactor and analyzed for ammonia-N, nitrite-N, nitrate-N, and phosphorous. The changes in the water quality parameters through the system components will be monitored, and their removal rates will be calculated to determine the performance of the S.B.R. and the effects on the algal reactor.Objective 3) Tank trials will evaluate the effect of various solid waste treatment regimes using different combinations of the filter feeder chamber, the radial flow separator, and the S.B.R. Three different system configurations will be constructed in triplicate. Each system will consist of a LMB tank (100 gallons), a filter feeder tank (20 gallons) stocked with tilapia, and algal reactor tank (20'diameter × 24" depth, water volume: 5000 gallons). The LMB tanks will be plumbed whereby effluent containing concentrated solid waste will be drained through a center bottom drain to the filter feeder tank. A continuous flow of water will be pumped to the LMB tank from the algal reactor. The algal reactor will be circulated continuously.The first system will be assembled without a radial flow separator or a S.B.R. The concentrated waste stream from the center bottom drain of the LMB tank will flow to the filter feeder tank and return to the algal reactor via a bottom drain in the filter feeder tank. The second system will be equipped with a radial flow separator but not a S.B.R. The concentrated waste stream from the center bottom drain of the LMB tank will flow to the filter feeder tank. The effluent from the filter feeder tank will flow to the radial flow separator. The majority of settleable solids will then be separated in the radial flow separator allowing the supernatant water to overflow into the algal reactor. The solids separated in the radial flow separator will be discharged daily to a drying bed. The third system will be installed with a radial flow separator and a S.B.R. The concentrated waste stream from the center bottom drain of the LMB tank will flow to the filter feeder tank. The effluent from the filter feeder tank will flow to the radial flow separator. Solids separated by the radial flow separator will continuously settle and accumulate and supernatant water from the radial flow separator will return to the algal reactor. Solid waste from the radial flow separator will be pumped to the S.B.R. once daily. The S.B.R. will be operated on a 5 minute fill, 6 hour anoxic react, 6 hour oxic react, 6 hour anoxic react, 5 hour oxic react, 45 minute settle, 10 minute decant cycle. Supernatant from the S.B.R. will discharge directly to the algal reactor. Water samples will be taken from the LMB tanks, the filter feeder tanks, and the algal reactors. Ammonia-N, nitrite-N, nitrate-N, phosphorus, and chemical oxygen demand (COD) will be measured daily at a scheduled time. An analysis of covariance (ANCOVA) test will be performed to identify differences in water quality between the different systems using SPSS 12 for windows (SPSS Inc., Chicago, IL). Sampling days will be considered as covariance, and the main effect comparison will be conducted using Bonferroni's method.Objective 4) Raw materials will be used to design and fabricate appropriate modifications to the following features of the in-pond tank design: a) screening of culvert on tank influent b) culvert transition to the channel supporting the waterwheel c) paddlewheel channel transition to the tank wall d) influent screen attachment to the tank walls/paddlewheel channel e) sidewall screen attachment to the tank walls f) water flow restrictor on the sidewall drain g) center drain screen h) filter feeder containment i) predator exclusion (birds/mink/otter/raccoon) and cover/shade j) access and manways k) mounting of oxygen saturator, water quality probes and automatic feeder. All modified components will be fabricated in the farm shop. A two tank arrangement as shown in figure 3 will be partially constructed with the required modifications. Throughout the fabrication process a written protocol will be created detailing the most efficient and effective manufacturing methods and materials identified. Total cost of a complete 8 tank system will be determined.

Progress 06/01/15 to 01/31/17

Outputs
Target Audience:Our primary target audience was the management and staff of J.M. Malone and Son, Inc. In addition to our primary target audience we demonstrated this project during farm visitsto: 1) four extension personel from Mississippi State University and the University of Arkansas at Pine Bluff, 2) sixteen commercial fish farmers and livefish distributorsfrom Lousiana, Arkansas, Texas, Mississippi, Missouri, Oklahoma, Ohio, Kentucky, Illinois, Alabama, 3)one contractor for Sukup Manufacturing Company Sheffield, IA ,4) two staff from Pentaire Aquatic EcoSystems of Apopka, Fl and 5) one staff from Fish Vet Group Portland, Me. Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided?This project provided individual study for the staff of J.M. Malone and Son, Inc. and three undergraduate students had the opportunity to work on the project for the duration of the research. How have the results been disseminated to communities of interest?In person farm tours were provided for extension personel from two local Universities, commercial fish farmers and live fish distributorsfrom surrounding States, an agricultural manufacturer and staff from two aquaculture consulting companies. This project was demonstrated during these farm tours and the concept, our approach, results of our research and commercialization plans were discussed. What do you plan to do during the next reporting period to accomplish the goals? Nothing Reported

Impacts
What was accomplished under these goals? Production of high value fish species in fish confinement systems such as the partitioned aquaculture system (P.A.S.)will allow for the better production and profitability. P.A.S. require modifications to capture solid waste in order to meet the water quality requirements of such species. A radial flow seperator and sequencing batch reactor were attached to a protoype in-pond tank operated in a modified P.A.S. and evaluated.Replicated pool trials were conducted to determine the effect of solid waste removal and processing on P.A.S. Appropriate modifications to the prototype were designed and fabricated resulting in the creation of a commercial scale second generation prototype. The first generation prototype in-pond tank rapidly concentrated solids waste to the center drain effectively removing 74.61% of all solids over 400 µm, 46.34% of all solids between 200 and 400 µm from the fish confinement. The R.F.S. effectively captured 90% of solids over 400 µm, 55% of solids between 200 and 400 µm, and 50% of solids between 100 and 200 µm from the center drain effluent. The S.B.R. removed approximately 86%, 56%, 31% and 67% of ammonia, nitrite, nitrate, and phosphorous added to the S.B.R. as solid waste over the course of the trial. Waste removal with R.F.S. improved minimum daily oxygen in P.A.S. algal reactors by10% and significantly reduced phosphorous, nitrate and nitrite levels in algal reactors. The second generation prototype design and fabrication process demonstrated that the in-pond tank design can be constructed from readily available galvanized, corrugated grain bin panels and that durable modifications to the influent, effluent, paddlewheel channel, motor mount, sidewall flow restrictor, screening, access and manways can be designed into a singular, uni-body, bolt together assembly easily incorporating shade and predator controls into design elements. The in-pond tank design operated in a modified P.A.S. has demonstrated the ability to revolutionize the production of high value species in the United States. However, solid waste capture with R.F.S. and processing with S.B.R. are subject to mechanical and biological failure. The development of more extensive solid waste processing and improved phytoplankton biomass assimilation methods will be key to improving production and making photosynthetic systems such as the P.A.S. commercially feasible.

Publications


    Progress 06/01/15 to 05/31/16

    Outputs
    Target Audience: Nothing Reported Changes/Problems:Objective 1. Water samples collected for TSS analysis were collected weekly rather than daily due to the combined travel and processing time required to analyze the samples. Objective 2. Water quality analysis was conducted three times weekly rather than daily for a majority of the trial to allow for additional water quality analysis of the SBR and the modified PAS system components. Several additional trials were arranged to analyze water quality within the SBR on an hourly basis so that the effect of alternating aerobic/anoxic phases could be understood.Additionally, water quality wasanalyzed three times per day once per month within each of the non SBR components to characterize water quality dynamics within the system.The treatment cycle of the SBR was varied throughout the trial in an attempt to improve its performance and gain a better understanding of its function. What opportunities for training and professional development has the project provided? Nothing Reported How have the results been disseminated to communities of interest? Nothing Reported What do you plan to do during the next reporting period to accomplish the goals?Objective 1. Further analysis of TSS data. Objective 2. Further analysis of water quality data from SBR and continued operation of SBR during the 2016 production cycle to further refine the process. Objective 3. The replicated algal reactor tank study will be conducted to determine the effect of solid waste collection and processing on the algal basin. Objective 4. Design and fabrication of appropriate modifications will continue. Feeder mounts, saturator mounts, center drain screens, filter feeder containment and predator exclusions will be designed and fabricated. The method,materials and costs of the final modificationswill be evaluated.

    Impacts
    What was accomplished under these goals? A 1/10th acre modified P.A.S. prototype was stocked with 2 inch feed trained largemouth bass and operated for 140 daysresulting in a harvest of 1018 pounds of 5 to 6 inch LMB fingerlings (10,180 pounds per surface acre of P.A.S., or 1.62 pounds per cubic foot of tank rearing space).Objective 1. Solid Waste Capture. Total suspended solids (TSS) capture rates were determined for modified P.A.S. prototype.Preliminary results indicate TSS capture rate measurements are highly dependent on flow rate, feed type and zooplankton/phytoplankton communities. Over the full course of the trial the radial flow separator was able to capture approximately 86% of solid waste larger than 400 um, 52% of solid waste between 200 and 400 um and 45% of solid waste between 100 and 200 um exiting the center drain of the tank. When conditions were optimized 90%, 64% and 50% of TSS larger than 400 um, between 200 and 400 um and between 100 and 200 um were captured respectively by the radial flow searator from the center drain effluent.Over the full course of the trial the cornell style drain design coupled with theradial flow separator was able to capture approximately 63% of totalsolid waste larger than 400 um and 30% of total solid waste between 200 and 400 um exiting the tank. When conditions were optimized 80% and 47% of TSS larger than 400 um and between 200 and 400 um were captured respectively from the total tank effluent.Objective 2. Solid Waste Processing. A sequenching batch reactor (SBR)recieving solidwaste from the radial flow separatorwas operated for 140 days using treatment cycles ranging from 4 hours to 24 hours.The SBR was dominated by heterotrophic bacteria which converted nitrogenous waste and phosphorous into biomass. Elevated ammonia and phosphorous levels following anoxic phases led to further trials evaluating treatment cycles up to 7 days.The SBR technology was determined to be highly susceptible to mechanical failure.Objective 4. Modifications for a Second Generation Prototype.The design of the second generation prototype was finalized and raw materials were used to construct appropriate medications for a commercial scale system.Galvanized, corrugated grain bin panels were assembled allowing the dimensions and orientation of the water influent and sidewall effluent channels to be determined based on: a desired 45 degree angle of water introduction to the tank, the calculated width of the paddlewheel required to pump the desired volume of water into the tank and the allowable gap provided by the removal of one full corrugated panel and the substitution of a short panel for an additional full corrugated panel. Grain bin door frame assemblies were modified to produce a transition from the corrugated panels to the influent and sidewall effluent screen assemblies and channels. Influent and effluent screen assemblies and screens were manufactured from sheet metal and stock aluminum respectively. Influent and sidewall effluent channels with integrated paddlewheel mounts and sidewall water restriction device were designed and manufactured from raw materials. Dimensions for feeder and oxygen saturator have been determined and manufacture of appropriate mounts is underway.Required accesses and manways were also constructed.

    Publications