Final Report Summary - FEED&TREAT (Optimizing water quality and treatment efficency in recirculating aquaculture systems for salmon smolt production through better adjustment of fish feed and water treatment devices.) Executive Summary:Feed and treat is an EU FP7 ‘research for SMEs’ project of two years by a consortium of partners aimed at optimising fish feed, water quality and treatment efficiency in recirculating aquaculture systems for salmon smolt production. To supply demand and reduce the environmental impact of salmon smolt production in the coming decades, the currently used flow-through plants need to be changed into recirculating aquaculture systems (RAS). Compared to the flow-through systems, RAS use freshwater and energy more efficiently, allow better control of water quality, bio-security and disease prevention, and produce a better final product.The project Feed and Treat aims to:• Improve treatability of fish excrements;• Optimise existing water treatment concepts used for recirculating aquaculture systems;• Re-use the organic load produced by a more effective mechanical treatment as a carbon source for the denitrification process;• Conserve energy by reducing the freshwater intake and wastewater outflow.Phase 1 of the project focuses on improving the treatability of fish excrements through diet manipulation of raw materials, the digestible protein to digestible energy ratio, and the grinding of raw materials and binders. Including the control diets of commercial feed, fish meal and a binder control, 33 diets were screened. We found that a significant increase in mechanical strength, important for improving the treatability of fish excrements, was linked to the use of raw materials and the inclusion of binders. The effects of both of the binders tested were comparable to those of the commercial control and no test diet showed significant negative effects on fish performance or health.In phase 2 we selected two optimal diets for further lab scale testing in both RAS and currently used flow-through systems. Six identical RAS were created for testing and were subsequently used to improve the treatment efficiency of mechanical treatment. These allowed the construction of complete mass-balances of the relevant substances and accurate determination of nitrification rates. A model was also created to optimize aerobic biological treatment by describing the relationship between feed consumption and waste load in Carbon/Nitrogen ratios. In the final phase of the project we tested our experimental results at an industrial scale. Moving bed dentrification trials were performed by ACUIT-T at the French smolt farm Salmo Sarl for salmon and by IAA and Veluvar for a pig waste stream. The selected diets were tested at a large scale at the Norwegian salmon smolt farm Smøla Klekkeri and Settefiskanlegg AS (SKS) and resulted in an optimal diet for salmon smolt production in recirculating systems.The project results that are the basis for the exploitation products include:1) A salmon smolt feed tested for RAS;2) A mechanical treatment concept for RAS leading to increased treatment efficiency;3) A biological treatment concept for RAS with reduced volume need;4) A moving bed based denitrification concept ready to use for salmon and pig;5) Design criteria/blueprint of future RAS and its commercial use.The adapted, RAS tested feed is expected to lead to significant treatment improvements and reducing the Carbon/Nitrogen ratio to biological treatment is expected to lead to an increased capacity in the Bioreactor and consequently higher water quality, where less feed is required and fish welfare is increased, thereby lowering mortality and reducing the required egg investment. Applying these improvements into state of the art RAS will produce cheaper and better products in both the salmon and pig farming industry.Project Context and Objectives:In Europe about 300 million salmon smolts were produced in more than 400 plants, as stocking material for the sea based net-cage production of salmon. The production is located are along the coastline of Norway, Scotland, Ireland, the Faroe Islands and Iceland. The production plants are operating mainly as flow-through system and depend on availability of large amounts of high quality water. The access to large water resources restricts production capacity and production facilities have problems satisfying the increasing demand of smolt for the marine based grow-out of salmon. In order to supply the demand and reduce the environmental impact of salmon smolt production, especially in respect to the demands of the European Water Framework Directive, most of the actual flow-through plants needs to be transformed to recirculating aquaculture systems (RAS) in the next decades. RAS for salmon smolt production have several advantages compared to flow-through operation: reduced freshwater requirements and energy consumption, better control of water-quality, improved bio-security and disease prevention and in the end a cheaper and better product.The water quality inside the RAS needs an optimal control through mechanical and biological treatment and other mechanisms (pH buffering, UV disinfection, etc.). Due to changing feed ingredients and cross interactions between feed, fish metabolites and the treatment system, the stable, optimal conditions, needed for successful economic production, cannot always be maintained throughout the production cycle. The feed is providing the needed nutrients and energy for fish growth. RAS use adds a new challenge as compared to flow-through as the microorganisms in the biological treatment need to grow and perform. Hence the feed in RAS has to serve two targets; the fish growth and the treatability of the fish metabolites. This treatment efficiency needs to be maximised to achieve sufficient water quality for the sensitive salmon smolts and a stable fish and system performance (stable microbiology and ion matrix in the water). Our consortium has been granted an EU FP7 research-for-SMEs project with the acronym Feed and Treat (duration 2 years; start date 01-02-2012, end date 31-01-2014) that has the following objectives:1) Improve treatability of fish excrements through definition of a “value added” feed aiming for state of the art fish performance and improved waste treatability by mechanical and biological filtration.2) Optimize existing water treatment concepts used for RAS for higher treatment performance and specific matching to the improved, adapted feed.3) Revise the denitrification step inside the system in order to reduce the increased organic load from a more effective mechanical treatment by using it as carbon source for the denitrification process.4) Reduce the freshwater intake/wastewater outflow and thus the energy consumption due to improved heat balance control and twice reduce the environmental impact.Project Results:A first major project objective was to improve treatability of fish excrements though diet manipulation on different scales (from experimental to commercial). The diets tested should support optimal water treatment in recirculating aquaculture systems for salmon smolts. Four variables were included; raw material, digestible protein to digestible energy ratio, grinding of raw materials and binders. Including different control diets (commercial control, fish meal control and binder control) a total of 33 diets were included in two screening trials. Significant increase in mechanical strength, important for improved treatability of fish excrements, was linked to use of raw materials, in particular Soy Protein Concentrate, and inclusion of indigestible binders. Both binders tested had effects comparable to the commercial control. None of the test diets had significant negative effects on the fish performance, nor did they compromise fish health. Two diets were selected for further lab scale testing in RAS. These two diets were compared to commercial control using duplicate treatments. The results showed that the faecal stability and mechanical treatability could be improved by inclusion an indigestible binder. However, the screenable fraction is low compared to the non-screenable fraction, limiting the scope of improvement of COD removal by mechanical filtration. Based on the screenability trial, COD/N ratio and the COD- and the N load to the biofilters can be lowered. Water samples representing each of the six RAS units have been analysed for bacterial diversity. From the lab scale RAS trial, a final diet was identified and progressed to a commercial scale trial. In collaboration with a smolt producer, and using their production facilities, a full scale test of the diet progressing through the previous steps was compared to the commercial control. The trial was set up using two identical RAS systems, each supplying four tanks that defined the two treatment groups. Hence, each treatment consisted of 4 tanks each holding approximately 100 000 fish. The fish were fed according to the farm management protocols. There were no differences in growth rates or apparent feed utilization, and all fish performed comparable to farm experience.A second major project objective was to improve treatment efficiency of mechanical treatment in the RAS. Three farms were sampled twice to establish a base-line. Treatment efficiency for TSS was 40% and for COD 14%. Fine particle filtration appeared not to be effective. In 2 experiments, 3 diets showing a large range in fecal stability, were tested in duplicate in replicated identical RAS. Particle size distribution (PSD) and Particulate Organic matter (POM) were determined at different times and places in the systems. In a bench-scale test, fecal material was first agitated and fractionation of fecal COD studied thereafter. The bench-scale test showed significant effects of diet formulation on fecal fractionation. However, on system level this effect could not be confirmed. The diets were tested at pilot scale but due to technical problem sampling of water quality was not possible. Alternatively, a new approach based on mass balances was used to analyse existing data.A third major project objective was to optimize aerobic biological treatment in RAS through nitrification by improved C/N ratios towards the biofilter. In this task it was demonstrated that the BOD/N ratio of the fecal waste produced by a commercial smolt diet is improved by inclusion of a combination of binders which improves screenability. The change in non screenable BOD/N ratio according to the best estimate is from 1.20 to 0.79. The potential theoretical predicted increase in nitrification rate for this change in BOD/N ratio is in the order of 20% based on literature as was the original target of the project. Overall it can be concluded that effects of fecal screenability on nitrification rates are relatively small and BOD can be omitted from design of nitrification systems. Biofilters in smolt farming operate far below maximum nitrification rates possible. Alternatively, significant reductions in biofilter size could be realised by increasing the load and TAN concentration to the biofilter in smolt farming. Analyses of farm data on biofilter performance demonstrated the effects of COD on nitrification. Moreover, the scope for more efficient biofiltration was shown by spiking samples of filtermedia with TAN and nitrite.A fourth major project objective was moving bed based denitrification, reducing the water intake to 100 L/kg. The Bioreactor layout had been developed by partner IAA. A set of these Bioreactors have been tested for pig slurry, representing the first application of the new moving bed based denitrification reactor. The reactor is closed and the moving bed is driven by internal gases produced during the denitrification process. Thus the oxygen content in the reactor can be kept at a minimum in order to perform denitirifcation. Industrial scale testing of denitrification has been finalised by Inter Aqua Advance with new SME partner Veluvar on pig slurry which was basis for a patent. The feasibility of denitrification for production of salmon smolts was demonstrated using fecal material screened by a drum filter by IMARES. Industrial scale testing of denitrification has been performed by ACUI-T at their partner Salmo SARL’s site on salmon smolt production. The purpose of the trial was to test the technical feasibility of a new reactor type for denitrification using a moving bed biofiltration system.All the improvements achieved in the project were synthesized in an attempt to come to a ready to implement RAS design for salmon smolt farming. As a result of testing mechanical treatment, aerobic biological treatment and denitrification in WPs 2-4, taken into account the diets tested, criteria were formulated. As a result of industrial scale testing in WPs 2-4 at SKS and Salmo SARL for salmon smolts, and Veluvar for pigs, data was raised to evaluate the selected optimal diet and, as far as possible under the complex conditions, the formulated criteria. Two patents will be (partly) based on the project’s results: on the optimal diet and on denitrification criteria. Publication of three scientific papers, a.o. to support the patents, and a review are foreseen, as well as several popular scientific papers. A final dissemination plan has been finalised. The final dissemination plan has described all means to communicate, disseminate and exploit the generated knowledge highly efficient towards a maximum profit for the SME in the project, in particular: appropriate dissemination channels, contact with stakeholders and ideas about the dissemination after the project lifetime.All required deliverables have been delivered. During RP1, the consortium agreement was signed and an agreement on IPR issues has been reached. Ethical clearance for RTD partners Nofima and IMARES has been reached. The project was kicked off with a project and PSC meeting in Ijmuiden (The Netherlands) and, after summer, a second project and PSC meeting was organised in Prague (Czech Republic) and linked to the AQUA2012 meeting where the consortium presented a poster. A draft dissemination and exploitation plan has been formulated, taking into account the results that were already achieved and the results to be expected. A press release resulted in publications in Aquaculture Europe (37(2):27), Fish Farming International (May, pp. 21) and several newspapers and internet sites. During RP2, annual project meetings have been organised in Yerseke and IJmuiden (The Netherlands) and a workshop in Trondheim (Norway). Furthermore, results have been presented at congresses in Denmark and Spain, a project video has been made and an open house for pig farmers is organised. MSc students have been trained through a RAS course and internships. Two patents will be (partly) based on the project’s results, publication of three scientific papers and a review are foreseen, as well as several popular scientific papers.The project results are the basis for the exploitation products include:1) A salmon smolt feed tested for RAS;2) A mechanical treatment concept for RAS leading to increased treatment efficiency;3) A biological treatment concept for RAS with reduced volume need as compared to the state of the art;4) A moving bed based denitrification concept ready to use and adjustable for other waste water streams;5) Design criteria/blueprint of future RAS and its commercial use.The adapted, RAS tested feed is expected to lead to significant treatment improvement and consequently to a reduced C/N ratio to biological treatment. The improved treatment is expected to lead to more capacity in the Bioreactor and consequently to a higher water quality. Improved water quality results from less feed that is needed and will lead to improved welfare status of the fish. The improved fish welfare status is expected to lead to less mortality and therefore less egg input in the production which consequently is cheaper.Integrating these improvements as achieved in the project into state of the art RAS will lead to an increased production, reduced investment costs and a better relation between invested money and achieved output. The project will generate additional efficiency for the production process resulting in cheaper and better products. Not only for salmon but also for pigs.Potential Impact:The relevant industrial project partners and their scopes are:• Inter Aqua Advance A/S (IAA): performing design, sales and construction of modern, recirculating aquaculture system (RAS).• Acui-T: performing equipment sales, and IAA RAS system sales in southwest Europe and fish farmer consultancy.• Sømna Settefisk A/S: performing fish farming for salmon smolt (This partner has participated in the consortium only during the first reporting period).• Veluvar: performing pig farming (During the second reporting period, this partner has replaced by the Dutch pig farm Veluvar, collaborator and client of IAA).• Lakeland smolt Ltd: performing fish farming for salmon smolt.• BioMar A/S: performing production and sales of fish feed.During the lifetime of the project, the following results were achieved as expected:Smolt feed tested for RAS systemsMechanical treatment concept of future RASBiological treatment concept of future RASMoving bed based denitrification stepDesign criteria (blueprint) of future RASThese results can be reduced to 3 main results, as the mechanical and biological treatment concept anyhow needs to be integrated in the blueprint of future RAS systems. Thus 3 main results which need their own exploitation and dissemination concept are:Smolt feed tested for RAS systems: For the smolt feed the main task was to prove the beneficial effect of the newly developed diet in modern RAS systems. This proof of principle has been performed at the smolt producing farm Smøla Klekkeri and Settefiskanlegg AS (SKS).Moving bed based denitrification step: The moving bed denitrification is the single most important instrument to reduce water need and water usage in modern RAS systems. However, the product can be used as well in other waste-water treatment applications as municipal waste-water or agricultural waste-water. After developing and fine-tuning the system this new reactor type equipment has to prove its treatment stability and day to day efficiency. This prove was performed by ACUI-T at the French smolt farm Salmo Sarl for salmon, and by IAA and Veluvar for a pig waste stream.Design criteria of future RAS: This result/product brings all the project results together into the next generation of RAS systems for smolt meaning the advances elaborated at the feed adaptation for RAS in combination with the optimized mechanical and biological treatment processes in the RAS systems, and along with a newly developed denitrification device, is the future of salmon farming in RAS systems. Additional important conclusions of the project were:We have reviewed the existing concepts and added own data. This concept shows what to do but was not tested, also because of the lacking sreenability methodology.We have launched a state-of-the-art approach testing from experimental scale to industrial scale.This product even goes beyond only smolt production. It is as well the blueprint for the future salmon industry on land. During the project lifetime, most of the products were not readily developed, however there is still a lot of input needed in order to improve the potential output of the project and the future dissemination and exploitation needs to be prepared.During the project lifetime, the most promising dissemination concept was by promoting the project idea. This concerned the novel approach in fine-tuning feed (as the single most important input into RAS) with the RAS technology in order to gain a multiple improvement on the water quality in RAS and as such a manifold improvement in the RAS performance and whole system revenue.This dissemination strategy implied that at the stage at the end of the first reporting period, only test results were presented, as demonstration was foreseen for the second reporting period and after the project lifetime meaning that information is distributed through personal networking and conference presentation. In addition also information that helps to improve the project results is gathered at the same events, and the potential competitive products are evaluated, in order to reach the target of getting new, improved products to the marked.The dissemination during the project lifetime needed to increase in activity along with the project development, and needed to shift from more informal and scientific presentations in the beginning to more commercial presentations and activity toward the end of the project and after the project lifetime.After the Project lifetime the dissemination is completely left over to the industrial partners. They perform the work by demonstration facilities. Here customer workshops are performed, to show the achieved results. The new products are used and implemented into new RAS facilities. Their superior performance, published by industry reports helps promoting the new developed products. In addition the developed products are further developed and adapted to additional fish species and application.Dissemination first reporting period (m1-9)Several consortium meetings have been organized during this period: March 6 2012: kick-off project meeting in Ijmuiden (The Netherlands).March 6/7 2012: first PSC meeting in Ijmuiden (The Netherlands).March 7 2012: site visit IMARES in Ijmuiden (The Netherlands).March 7 2012: site visit SILT in Ijmuiden (The Netherlands).September 5 2012: project meeting in Prague (Czech Republic, linked to AQUA2012).September 6 2012: PSC meeting in Prague (Czech Republic, linked to AQUA2012).September 19 and October 19 2012: WP1 Skype meetings with partners IMARES, IAA, Nofima and Biomar in relation to milestone M1.1.October 29 2012: site visit pig farm Veluvar in ‘t Harde (The Netherlands) in relation to DA 2: Denitrification implementation to test applications in treatment of other waste streams from outside aquaculture.As for external dissemination, dissemination channels have been used: 1. the press release at the project start; 2. the participation of 9 major actors of the Feed &Treat project at the Aqua 2012 meeting in Prague; 3. The participation of IAA as SME in the project at significant smolt RAS specific industry events and trade shows as Aqua Sur in Chile and the "Smolt production in the future – 2nd Conference on Recirculation in Aquaculture" on Sunndalsøra 23-24.; 4. A poster presentation of the project was shown at the Aqua 2012 show in Prague. The demonstration on site had not started jet, as not enough results had been achieved for onsite demonstration. The objective to convince stakeholders in the Salmon industry about the advantages of improved RAS has been approached mainly through the SME IAA participating at two major events for the salmon industry. 1. The Aqua Sur in Puerto Mott in Chile (10 – 13. October 2012) and the 2.nd Conference on recirculation aquaculture in Sundalsøra, (Norway) entitled “smolt production in the future” (23 – 24. October 2012). Here the latest achievements of the project were discussed with relevant stake holders and the scientific and industrial world of smolt production in Norway. More events of this kind to come. A first website was launched: http://www.wageningenur.nl/nl/show/Feed-Treat-Towards-environmentally-friendly-aquaculture-for-Atlantic-salmon.htm.Several publications were released:Scientific publication aimed at the aquaculture industry and associations, extension officers, coordinators/partners of EC-related projects, scientists/academia, educators, NGOs and EU project officers:Palstra, A.P. Kamstra, A. , Eding, E. , Saether, B-S, Sindilariu, P-D, Olesen J.O. Leclerq, D., Osmundsen, J., Polanski, R., Holm, J. (2012) Optimizing water quality and treatment efficiency in recirculating aquaculture systems for salmon smolt production through better adjustment of fish feed and water treatment devices. World Aquaculture & European Aquaculture 2012. September 1-5, Prague (Czech Republic).Popular scientific publications aimed at the aquaculture industry and associations:Towards environmentally friendly aquaculture for Atlantic salmon. Aquaculture Europe VOL. 37 (2) JUNE 2012 pp. 27 Salmon, but better. Fish Farming Int. MAY 2012 pp. 21 Publications aimed at the public at large in regional and national dutch newspapers:Schoner water voor kweekzalm. De Laatste Paling. 31 MAY 2012.IMARES streeft naar schoner water voor kweekzalm. WaterForum.net. 30 MAY 2012.Zalmkweek in gesloten systeem. BioNieuws. 5 MAY 2012. pp 7 Schoon water voor kweekzalm. Volkskrant. 28 APRIL 2012. IMARES coördineert tweejarig onderzoeksproject: Optimaliseren van kweek zalmsmolts. Visserij Nieuws. 20 APRIL 2012. Atlantische zalm geboren. Provinciale Zeeuwse Courant. 13 APRIL 2012.Dissemination second reporting period (m10-24)The 1st year project and PSC meeting were organised on March 11-13 in Yerseke, The Netherlands. A course on RAS was organised at Wageningen University by Andries Kamstra and Ep Eding aimed at aquaculture engineers. In the period April-May, IAA has been developing the denitrification unit at Veluvar being on site continuously. On May 7 (2013), Arjan Palstra (IMARES) visited the site at Veluvar. On September 4-6, Andries Kamstra (IMARES) attended the Aquaculture Innovation Workshop in Shepherdstown (US).On August 11 (2013), SME Partner IAA gave an oral presentation during the Aquaculture Europe meeting (conference) in Trondheim in the session Land Based Farming Technologies, organized by the Aquaculture Engineering society, entitled “Waste matrix in state of the art RAS for salmon smolt: What are the next development steps needed?”.On August 12 (2013), SME partner IAA organised a workshop as satellite event of AE2013 and AquaNor in the Trondheim Spektrum in Trondheim, Norway. The workshop was entitled “Industrial testing of Feed and Treat experimental results” and had as objective to give an overview of the results of experimental scale testing, a phase in the project that has been finished. Invited guests to the workshop were representatives of the Norwegian salmon smolt farm Smøla Klekkeri and Settefiskanlegg AS (SKS)On August 12 (2013), the consortium met with representatives of SKS at Biomar’s House, Trondheim, Norway. The presentations presented at the workshop functioned as basis for a discussion on the industrial testing of Feed and Treat experimental results with representatives of SKS: on the opportunities to perform these trials at SKS and the planning of activities.During September-October 2013, several Skype meetings were held on discussing the industrial testing at SKS (Norway).During October-November 2013, François Xavier Saulnier (ACUI-T) visited Salmo SARL several times to perform denitrification trials on salmon smolts.In October 2013, Jens Olesen (IAA), Jorgen Holm (Biomar) and Andries Kamstra (IMARES) visited the the 2nd workshop on RAS, Aalborg, Denmark, in parallel with DanAqua and DanFish International 2013. Andries Kamstra (IMARES) presented Feed and Treat results at the the Nordic RAS workshop. He is preparing a paper for a special issue of Aquaculture Engineering on the proceedings of this workshop.In November 7-11 2013, Bjorn-Steinar Saether (Nofima) attended the Aquaculture 2013 event in Las Palmas, Gran Canaria, (Spain).In November 2013, Bjorn-Steinar Saether (Nofima) and Andries Kamstra and Ewout Blom (IMARES) visited SKS in Norway to perform fish and system measurements.In January 29-31, the 2nd year project meeting and PSC meeting were organised in Ijmuiden (The Netherlands).During RP2, partner SSF was replaced by Dutch pig farm Veluvar. Smolt farm measurements were performed at the Norwegian SME smolt farm SKS and the French salmon smolt producing SME Salmo sarl.The novel improved and extended website was introduced and launched: http://www.feedandtreat.eu. The website has been updated every three months ever since. A final update is being planned for. The consortium wants to keep the website alive also after the project’s lifetime and continue paying for updating it 4 times per year. Public deliverables and the publishable summary will be uploaded on the website.A video film was made on the project’s results. The videoclip was uploaded on Youtube. Videoclip was advertised by the coordinator and IMARES through social media e.g. LinkedIn groups Aquaculture and Recirculating Aquaculture Systems. The videoclip was also published by Hatchery International of 17/02/2014: http://hatcheryinternational.com/recirc/Feed-and-treat%3A-optimizing-salmon-smolt-ras/. The video has also been used by IAA and IMARES on an exhibition in Abu Dhabi. As for scientific publications and patents, two patents will be (partly) based on the project’s results, publication of three scientific papers and a review are foreseen, as well as several popular scientific papers.As planned, the novel approach of fine tuning feed and RAS technology has been disseminated. During the first reporting period mainly by presenting the project and its objectives, and during the 2nd reporting period by presentation of results and demonstration activities which will continue after the project’s lifespan. Currently, dissemination activities increase and shift from more informal and scientific presentations in the beginning to more commercial presentations and activity toward the end of the project and after the project lifetime.The project results will promote RAS a husbandry method in the salmon production markets in the USA, Canada and Chile as the other major salmon producers outside Europe. The reduced fresh-water need and reduced nutrient release from salmon smolt production will clearly reduce the environmental impact to a minimum in the sensitive coastal areas, which are actually the centre of salmon smolt production. This will allow exporting European technology to the outside and sustaining the European position as market leader for innovation in fish culture.Through its result, the project touches the sustainability triple P on a European and global level: People: smolt production will go on and provide work and income to people, the life quality of the European population will be improved, as smolt production becomes more sustainable and therefore social more acceptable. Furthermore is the knowledge base on smolt production increased and disseminated. The planet component will obviously improve as less water is used, fewer nutrients are emitted and smolt mortality will decrease. Furthermore a better growth rate is expected, correlated with a better feed conversion ratio. Last but not least profit is improved, as more products are generated with less input and at relatively low investment rates. The project is therefore serving the overall idea of 2 times more with 2 times less.List of Websites:www.feedandtreat.eu
