UAE Shrimp Farm RAS Design
RASПланування

UAE Shrimp Farm RAS Design

Aqua Bridge - 250 MT Annual Production

Клієнт

Aqua Bridge / Confidential Client, United Arab Emirates

Місце

United Arab Emirates

Рік

2022

Види

Pacific White Shrimp (Litopenaeus vannamei)

Потужність

250 tonnes/year

Огляд проекту

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.

Ключові показники

250

Тонн/рік

6

Циклів/рік

45t

Біомаса

4000m³

Об'єм води

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

Інженерні виклики

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.

    • Наше рішення

    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.

    Технічні характеристики

    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

    • Фінансові показники

    CAPEX

    $1,240,000

    Річний OPEX

    $917,000

    Річний дохід

    $1,690,000

    Річний прибуток

    $652,000

    Собівартість

    $4.60/kg

    Маржа

    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.

    Результати проекту

    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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