RASConstruction Phase

UAE Shrimp Farm RAS Design

Aqua Bridge - 250 MT Annual Production

Client

Aqua Bridge / Confidential Client, United Arab Emirates

Location

United Arab Emirates

Year

2022

Species

Pacific White Shrimp (Litopenaeus vannamei)

Capacity

250 tonnes/year

Project Overview

Designed a state-of-the-art super-intensive shrimp production facility for the harsh desert climate of the UAE, utilizing advanced biofloc technology and zero-discharge water management.

This project represents a comprehensive engineering solution for producing 250 tonnes of Pacific White Shrimp annually in one of the world's most challenging environments. The facility uses a multi-phase RAS approach with biofloc technology to maximize production efficiency while minimizing water consumption and environmental impact.

The system includes nursery tanks (2 × 150 m³), intermediate grow-out tanks (2 × 350 m³), and final production tanks (4 × 750 m³), supported by advanced water treatment systems including biofilters, mechanical filtration, ozone treatment, oxygen injection, and UV sterilization.

Key Performance Metrics

250

Tonnes/Year

6

Cycles/Year

45t

Standing Biomass

4000m³

Water Volume

Footprint: 2,000 m² per production unit
Water Volume: 4,000 m³ total
Water Exchange: <5% per day
Oxygen Consumption: 750g per kg feed
Feed Conversion Ratio: ≤1.55
Survival Rate: 57% (after culling)
Market Size: 16-25g average
Energy Demand: 250 kW constant

Engineering Challenges

The UAE presents unique challenges for aquaculture:

- Extreme outdoor temperatures reaching 45-50°C in summer

  • Severe water scarcity in a desert environment

  • High biosecurity requirements to prevent disease introduction

  • Critical need for reliable oxygen supply in high-density production

  • Limited local expertise in super-intensive shrimp farming

    The client required a facility that could operate year-round in these conditions while maintaining world-class production efficiency and profitability.

    • Our Solution

    Our engineering team developed a comprehensive solution addressing each challenge:

    Climate Management: Insulated building design with efficient HVAC systems and energy-efficient cooling to maintain optimal water temperature despite extreme external conditions.

    Water Conservation: 95% water recirculation with minimal discharge, integrated with desalination for makeup water. Total system volume of 4,000 m³ with less than 5% daily exchange.

    Biosecurity: Multi-barrier approach combining ozone treatment, UV sterilization, and advanced filtration. Quarantine protocols for incoming stock.

    Oxygen Supply: On-site oxygen generation (Linde SOLVOX system with 50-60 mg/L capacity) plus emergency LOX backup, with automated monitoring and failsafe systems to ensure continuous supply.

    Water Treatment: 500 kg feed/day capacity biofilter, drum filters (60/80 micron), degassing units for CO₂ and nitrogen removal, and comprehensive support infrastructure including hatchery (4 million larvae/month capacity), automated feeding systems, and wastewater treatment with effluent processing and denitrification.

    Technical Specifications

    System Components:

    Phase I - Nursery (Weeks 1-2):

    • 2 × 150 m³ concrete tanks

    • Biofloc establishment phase

    • Intensive monitoring and feeding

      Phase II - Intermediate (Weeks 3-4):

    • 2 × 350 m³ concrete tanks

    • Accelerated growth phase

    • Optimized stocking density

      Phase III - Growout (Weeks 5-12):

    • 4 × 750 m³ concrete tanks

    • Final production phase

    • Maximum biomass density: 15.36 kg/m³

      Water Treatment Systems:

    • Biofilter: 500 kg feed/day capacity

    • Mechanical Filtration: Drum filters (60/80 micron)

    • Ozone Treatment: For pathogen control

    • Oxygen Injection: Linde SOLVOX system (50-60 mg/L capacity)

    • Degassing Units: CO₂ and nitrogen removal

    • UV Sterilization: Water disinfection

      Support Infrastructure:

    • Hatchery: 4 million larvae/month capacity

    • Feed Storage: Automated feeding systems

    • Oxygen Generation: On-site PSA system

    • Wastewater Treatment: Effluent processing and denitrification

    • Desalination Unit: Freshwater production

    • Emergency Backup: LOX system + generators

    Financial Performance

    CAPEX

    $1,240,000

    Annual OPEX

    $917,000

    Annual Revenue

    $1,690,000

    Annual Profit

    $652,000

    Production Cost

    $4.60/kg

    Profit Margin

    38.65%

    ROI

    ~2 years

    Projected financial performance assumes $7.50/kg sale price. Environmental benefits include minimal water consumption (<125 m³/day discharge), zero environmental impact (closed system), and local food production in food-insecure region.

    Project Results

    Technical Performance:

    • Annual production capacity: 250 tonnes whole shrimp (HOSO)

    • Standing biomass: 45 tonnes

    • 6 production cycles per year

    • Feed Conversion Ratio: ≤1.55

    • Survival rate: 57% (after culling)

    • Market size: 16-25g average

      Financial Performance (Projected):

    • CAPEX: $1.24M USD (design + equipment)

    • OPEX: $917K USD annually

    • Production cost: $4.60/kg

    • Annual revenue: $1.69M (at $7.50/kg)

    • Annual profit: $652K USD

    • Profit margin: 38.65%

    • ROI: ~2 years

      Environmental Benefits:

    • Minimal water consumption (<125 m³/day discharge)

    • Zero environmental impact (closed system)

    • Reduced reliance on wild-caught shrimp

    • Local food production in food-insecure region
    "Vismar Aqua's engineering team demonstrated exceptional expertise in designing our shrimp facility. Their attention to detail, understanding of biofloc technology, and ability to adapt to our local conditions was impressive. The system design is world-class."

    Project Manager

    Aqua Bridge Project, UAE

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