SHELLFISH PRE-INDUSTRIAL PILOT DEFINITION STUDY

SHELLFISH PRE-INDUSTRIAL PILOT DEFINITION STUDY ACCELERATED DETOXIFICATION SYSTEM FOR LIVE MARINE SHELLFISH CONTAMINATED BY PSP TOXINS CRAFT CONTRACT N° QLK1-CT-2002-72076 aDELIVERABLE D18a

TABLE OF CONTENTS SHELLFISH PRE-INDUSTRIAL PILOT DEFINITION STUDY ..........................................................1 1

OBJECT ...............................................................................................................................................2

2

SPECIFICATIONS REMINDER ......................................................................................................2 2.1 GENERAL OBJECTIVES ..............................................................................................................2 2.2 CONSTRAINTS ............................................................................................................................2 2.2.1 Environmental constraints .........................................................................................2 2.2.2 Mechanical constraints ..............................................................................................2 2.2.3 Biological constraints ................................................................................................2 2.2.4 Interface constraints ..................................................................................................2

3

SYSTEM DESCRIPTION ..................................................................................................................3 3.1 CIRCULATION ............................................................................................................................4 3.1.1 Closed circuit.............................................................................................................4 3.1.2 Recirculation .............................................................................................................4 3.1.3 Fresh seawater ...........................................................................................................5 3.2 WATER QUALITY CONTROL ......................................................................................................6 3.2.1 Scope .........................................................................................................................6 3.2.2 Measures....................................................................................................................6 3.2.3 Correction..................................................................................................................7 3.2.4 Effluent treatment......................................................................................................9 3.3 STORAGE ...................................................................................................................................9 3.3.1 Baskets ......................................................................................................................9 3.3.2 Tanks .........................................................................................................................9 3.4 FEEDING ....................................................................................................................................9 3.4.1 Distribution..............................................................................................................10 3.4.2 Control.....................................................................................................................11 3.5 SUPERVISION ...........................................................................................................................12 3.5.1 Regulation ...............................................................................................................12 3.5.2 MMI ........................................................................................................................14 3.6 ANCILLARIES ...........................................................................................................................14 3.6.1 Power supply ...........................................................................................................14 3.6.2 Safety.......................................................................................................................14

ANNEX 1 : PILOT OVERALL DIAGRAM.............................................................................................15 ANNEX 2 : BILL OF MATERIALS .........................................................................................................16

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1 OBJECT The goal of the definition study is to give a design a solution compatible with the users technical requirements, expressed in the specifications, in order to manufacture a SHELLFISH pilot compliant with the needs. 2

SPECIFICATIONS REMINDER

2.1 GENERAL OBJECTIVES The specification sets several objectives to be obtained: o Detoxification duration between 3 and 6 days o Processing capacity from 1 to 5 tons (150kg for the pilot) o Maximal capital cost of 450k o Working cost between 0,03 and 6 /kg o Size from 10 to 20 m2 o Daily management between 20 and 60min 2.2 CONSTRAINTS The specifications also impose several constraints : 2.2.1 o o o o o

Environmental constraints Temperature range from +5°C to +45°C 100 % Humidity Wind: 100km/h max Exposure to sun Exposure to rain

2.2.2 o o o o o

Mechanical constraints 150kg of shellfish to be treated 1,5m3 of stocking distributed in 3 PALLOX (or equivalent) tanks of 0,5m3 0,5m3 buffer tank 2m3/h flow in treatment loop (complete renewal of the water) suitable for the holding of live molluscs intended for food purposes (plastics, stainless steel, etc)

2.2.3 o o o

Biological constraints constant water temperature in operation of 16°C Dissolved oxygen rate close to 90% of saturation Ammonia rate in treatment loop lower or equal to 0.8ppm

2.2.4 Interface constraints o PC environment o Process control of : - flow - phytoplankton supply - fresh seawater supply o Supervision of different parameters o Sound and visual warnings o Easy to use

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3 SYSTEM DESCRIPTION The prototype is based on a closed circuit system: the water continuously circulates through the various elements of the circuit.

SUPERVISION FEEDING

TREATMENT

S COQUILLAGES H E L L F I S H CLOSED LOOP

Figure 1 : Principal plan

The supervision system controls the food supply for the shellfish, and the water quality. The overall diagram is in annex 1. The bill of materials is in annex 2. SHELLFISH ACCELERATED DETOXIFICATION SYSTEM

WATER CIRCULATION

WATER QUALITY CONTROL

SHELLFISH STORAGE

FEEDING

SUPERVISION

ANCILLARIES

PUMP

MEASUREMENT

BASKETS

DISTRIBUTION

PROCESS CONTROL

POWER SUPPLY

VALVES AND WATERLINES

CORRECTION

TANKS

CONTROL

MMI

SAFETY

FRESH WATER

EFFLUENT TREATMENT

Figure 2 : Product Breakdown Structure

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3.1

CIRCULATION

3.1.1 Closed circuit The closed circuit constitutes the backbone of the system. Water and food will be distributed through it to the shellfish storage tanks.

Storage tank

Interchange tank for

Storage tank

Storage tank BUFFER TANK

TEMPERATURE TANK

cleaning

Figure 3 : Closed circuit

Piping will be sized in order to allow a flow of 2m3/h. Water supply will be regulated by manual valves. Overflow pipes will empty the excess of water in a conduit which, by gravity, will forward it to the buffer tank, itself emptying the overflow to the temperature tank. 3.1.2 Recirculation The specifications lays down a constant flow of 2m3/h in the treatment loop and for this reason the system is equipped with a recirculation system enslaved to this value. The pump that will be used has a fixed flow of 15m3/h to guarantee compatibility for the industrial scale. In order to provide the required flow, a proportional solenoid valve, enslaved through the interface to a vane flow meter, will be implemented on the outlet of the pump. The pump will be a vortex pump in order to avoid phytoplankton damage when pumping. Proportional solenoid valve

Interface

Non return Non return flap valve valve

Value 13m3/h

ON/OFF

Measure

2m3/h

Flow meter

15m3/h

Proportional solenoid valve

Vortex pump

Figure 4 : Recirculation system

A feedback loop will be added to prevent overload (and damage) to the pump. It will constitute a second proportional solenoid valve, command of which will be the duplicate of SHELLFISH-310-01a/07-04

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the first one, and a non return flap valve. The recirculation system will pump water in the temperature tank. 3.1.3

Fresh seawater

Filtering Fresh seawater will be pumped onsite. If the sites water supply does not already include it, the water will be filtered in order to eliminate organic and mineral particles. Mineral particles elimination will be performed by a mechanical filter. Organic particles smaller than the mechanical filter mesh size will be sterilized with a U.V. filter. Regulation Fresh seawater supply in the circuit will allow losses generated by the detoxification process to be compensated for, particularly at the start of detoxification and at tank cleaning. It will also allow protect shellfish from being exposed to air should there be a leak in the circuit. Closed loop

RECIRCULATION PUMP

High level sensor

Low level sensor

BUFFER TANK

TEMPERATURE TANK

MECHANICAL FILTER

UV FILTER

Solenoid valve

SEA WATER

Figure 5 : Fresh seawater supply

Fresh seawater supply will be driven by two actuating signals corresponding to levels in the temperature tank : o « Low level »: minimum height. o « High level »: maximum height. When a leak occurs, the interface activates water supply when a low level is detected. Water distribution will stop as soon as maximum level is reached. SHELLFISH-310-01a/07-04

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3.2

WATER QUALITY CONTROL

3.2.1 Scope The quality of the water is the other driving element of the process. Detoxification process will be all the more effective with shellfish being kept in an optimal environment. Thus it will be necessary to measure various parameters of the circuit and to use correction devices if necessary to maintain these optimal conditions. 3.2.2

Measures

Temperature Temperature measure will be provided by a probe immersed in the circuit, either by tapping, or by derivation. The sensor will be made of a pt100 head type, coupled with a transmitter supplying standard electrical signals (4-20mA or 0-5/10V); a B class accuracy ( 0.3°C) will be sufficient. Measurement will be done continuously.

Figure 6 : Temperature probe and transmitter

Dissolved oxygen (DO) DO measurements will be made continuously; the sensor will be located either in a storage tank or in the circuit. The sensor probe will be able to measure values in a range centred on 90% saturation. The transmitter will provide standard electrical signals (4-20mA or 0-5/10V). However, this kind of sensor is fragile, so the equipment chosen would be the one which need the less maintenance possible (cleaning, electrolyte replacing).

Figure 7 : DO sensor

Nitrogen salts There is no nitrogen salts sensor which is able to provide measures in seawater around the limit threshold of ammonia in the circuit (0.8ppm), because of interference created by other ions in seawater similar to ammonia. SHELLFISH-310-01a/07-04

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For this reason discrete measurements will be made manually. 3.2.3 Correction To answer the mentioned quality criteria the system will be provided with regulatory devices. Temperature The pilot will be equipped with a heating/cooling system to keep water temperature at the set temperature of 16 0C, regardless of the external ambient temperature. A reversible AQUACLIM 10 from PSA s will be used.

Figure 8 : AQUACLIM 10 from PSA s

AQUACLIM 10 is an automatic temperature regulator usually used in fish farming applications. Its features allow us to use it for both pilot and industrial application. The desired temperature value is manually entered on a control panel, the AQUACLIM10 isn t designed to be remotely operated. AQUACLIM 10 features o Automatic regulation o Minimum Inlet flow : 8m3/h (in order to avoid water frost in the cooling circuit) o Hydraulic connection : 50mm o Power supply : 230V/single phase/50Hz o Current consumption: 13A o External installation Considering the inlet flow necessary for correct operation, AQUACLIM10 cannot be connected in serial to the pilot water circuit. That s why it is necessary to create a secondary water cicuit dedicated to temperature regulation which will have to be transparent towards the flow of the first one. AQUACLIM 10 Secondary circuit (8m3/h)

TEMPERATURE TANK

Main circuit (2m3/h)

Figure 9 : Secondary water circuit for temperature

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Inlet and outlet flow are equal so that the volume in the temperature tank remains constant. Thus, flow in the first circuit is not perturbed, and water from the temperature tank is to the wished value. Dissolved oxygen Oxygen supply will be made by a compressor, which is going to distribute the compressed air in the storage tanks. Ambient air

COMPRESSOR

Storage tanks

Figure 10 : Oxygen supply

Nitrogen salts The reduction of the concentration in nitrogen salts will be made by a biological filter. A bacterian population will be put in culture in a bowl. These bacteria are going to feed on present nitrogenous elements in the water and are going to transform them into other non harmful elements for shellfish. To do it, bacteria need a filtration medium of a clay expanded type, with a minimum average diameter of 3mm so that it doesn t retain phytoplankton particles.

Figure 11 : Biological filter

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Filter features o Filtering surface: 0.1111m2 o Filtering diameter : 37,6cm o Treatment volume : 0,14m3 o Minimal height: 1,2m o Treatment flow : 2m3/h o Crossing duration : 4min Bacterian development In order to reduce the bacterian proliferation in the circuit, an UV filter will be used to sterilize the water. It will have to work cyclically during a definite time. When it isn t in function, it will have to be transparent towards the treatment loop. To avoid phytoplankton sterilizing when the UV filter is running, the use of various algal cells recovery systems (pocket filter, hydrocyclone) will be tested. 3.2.4 Effluent treatment The specifications book implies that all the effluents generated by the system must be cleaned before being thrown back to avoid contagion of the environment by the toxic algae. So each tank will be equipped with a draining circuit which connected to a portable pump will forward waste water to a specific tank. The water so collected will be treated by sodium hypochlorite or other chemical treatment. 3.3

STORAGE

3.3.1 Baskets Shells will be stored within tanks in plastic baskets. 3.3.2 Tanks Tanks for the pilot will be 600l pallox. The pilot will include 8 tanks: o 4 tanks for shellfish storage (3 working and 1 for cleaning) o 1 buffer tank o 1 temperature tank o 1 tank for phytoplankton storage o 1 tank for effluent treatment 3.4 FEEDING Feeding is a key point of detoxification process. While supplying a food suitable for detoxification and in optimal quantity, the process of decontamination can be completed in 6 maximum days. On the other hand, phytoplankton is the main operating cost for the producer and that is why it must be exactly distributed, by avoiding any wasting.

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Interface

PUMP

Phytoplankton

Closed loop

Fluorometer Figure 12 : Feeding

3.4.1 Distribution Distribution will be made by a peristaltic pump because: It is more accurate than an impeller pump Phytoplankton isn t damaged when pumping. It is a modular piece of equipment whose flow range can be modified just by changing pipe diameter. The specifications indicate that phytoplankton flow to be injected in the circuit has to be at least of 10 l/h. This value corresponds to a minimum feeding rate for 150 kg of shellfish, and depends on phytoplankton concentration. If we consider that this value represents the optimal average flow, we shall thus use for the dimensioning the following flow range: 5 - 20 l/h. So we shall have a wide enough variation range to adapt the supplied quantity of phytoplankton. Furthermore, the pump will have to suit for both pilot and industrial application. It will thus be necessary to choose the pump according to flow specification for the prototype (2m3/h) extrapolated to the industrial application: Flow extrapolation Minimum flow

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Mass of shellfish to treat (in kg)

l/h

l/min

ml/min

150

5,0

0,1

83,3

1000

33,3

0,6

555,6

5000

166,7

2,8

2777,8

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Medium flow Mass of shellfish to treat (in kg)

l/h

l/min

ml/min

150 1000 5000

10,0 66,7 333,3

0,2 1,1 5,6

166,7 1111,1 5555,6

Maximum flow Mass of shellfish to treat (in kg)

l/h

l/min

ml/min

150 1000

20,0 133,3

0,3 2,2

333,3 2222,2

Figure 13 : Flow extrapolation for peristaltic pump

The peristaltic pump will have to answer the following requirements: Flow range : 5-660 l/h Remotely operated Protection : IP54 or better Power supply 230V/single phase/50Hz 3.4.2 Control Control of phytoplankton in the circuit will be made by a fluorometer, which is going to measure chlorophyll concentration. This measure will allow to slave the peristaltic pump flow to a wished value. The used device will be a SEAPOINT FLUOROMETER, already used for experiments.

Figure 14 : SEAPOINT fluorometer

a. o o o o

Features Outlet signal : 0-5V Time constant : 0,1s 4 measure ranges : 0-5 g/l, 0-15 g/l, 0-50 g/l, 0-150 g/l accuracy : 0,02 g/l

b. Power supply o 8-20VDC o 15mA (27mA peak)

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c. Pin configuration

1 3.4.2.1.1.1.1 Vss 2 3.4.2.1.1.1.2 V+ 3 3.4.2.1.1.1.3 V4 3.4.2.1.1.1.4 Vdd 5 6

3.4.2.1.1.1.5 Range selection

Pin 5 +5V

pink 6 +5V

Range 0-5 g/l

+5V 0V

0V +5V

0-15 g/l 0-50 g/l

0V

0V

0-150 g/l

Figure 15 : SEAPOINT pin configuration

3.5 SUPERVISION Supervision system will have to manage control functions and the Man-Machine Interface (MMI). 3.5.1

Regulation

Figure 16 : Data treatment chain

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Electrical signals coming from sensors will be forwarded to the regulation system. The signals will be captured by the data acquisition board which will digitize them. Once these data are acquired, the regulation system will process the data and send to the actuators the correct command signals to balance the various control factors. Processing and control The processing and control functions will be performed by a PC. Furthermore, considering the working environment, it will have to meet a minimum IP54 tightness standard (protection against dust and water jets). It will consist of a screen, a central processing unit, a keyboard and a pointing device. It will have two PCI ports for data acquisition and generation boards.

Figure 17: Examples for computer equipment

Acquisition and generation Acquisition and generation functions will be done by specific PC extension boards. These boards will be chosen from National Instruments in order to guarantee operating compatibility with development software (National Instruments LabWindows CVI); they will be designed for a PCI bus extension. a. o o o

Acquisition board : Inputs : at least 5 Input types : 0/4-20mA, 0-5/10V (plus TOR, an frequency if possible) Accuracy : 12bits minimum

b. o o o

Generation board Outputs : at least 3 Output types : 0/4-20mA, 0-5/10V, TOR Accuracy : 12bits minimums

4-20mA and 0-5V are kind of signals the most commonly used in industry. A 12bits accuracy provides a range of 4096 values possible for a signal. For example, a 0-5V signal sampled on 12bits provides a 0.0012V accuracy. Signal conditioning Signal conditioning will be made necessary because of variety of signals and ranges. This function will be done by a specific electronic board to be made.

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Software The software will be developed with LabWindows CVI 6 from National Instruments. It is a development tool in C language, dedicated to process control and MMI. 3.5.2 MMI The MMI will inform user about system status, it also allows the operator to act on the different operating parameters. Furthermore, they will have to include the possibility of saving data acquired during the system operating cycle. For this purpose the PC will have an external storage device (floppy disk or CD-ROM). The MMI will also have to be able to inform the user of a malfunction. That is why besides warnings on the screen, there will be sound and visual alarms allowing the operator to identify the kind of breakdown.

Figure 18 : Sound and visual alarms

3.6

ANCILLARIES

3.6.1 Power supply Electrical case will provide power to different devices. Most of them will work on 230VAC/single phase/50Hz; however it will be necessary to foresee 12VDC and 24VDC beams to feed particular sensors (like the fluorometer which requires an 8-20VDC line). 3.6.2 Safety To protect infrastructure persons, the electrical supply will be conditioned in a waterproof case and have got the following safety circuits: o 1 emergency switch o 1 overall circuit breaker o 1 differential circuit breaker 30mA o 1 power LED

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ANNEX 1 : PILOT OVERALL DIAGRAM

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ANNEX 2 : BILL OF MATERIALS

APPARATUS A CIRCULATION A1 WATER CIRCULATION

DESCRIPTION

A11 A12 A13

Pump Solenoid valve Flow meter

A14

Non-return valve

A2

DETAILS

With vortex head pump Piloted, proportional, diam. 40 Pallets flow meter

QTY

4 2 1 1

WATER NETWORK Piping Valve

PVC Manual, PVC

1 4

A31

Bactericide treatment

UV filter, 27mJ/cm to 9m, PVC body

1

A32

Mechanical treatment

A33 A34

Valve Level sensors (high and low)

Piloted, ON/OFF SWITCH YES/NO sensors

1 2

Piping Valve

PVC Manual, PVC

1 4

Heater/chiller Sensor

PSA AQUACLIM 10 Pt100 + transmitter

1 1

Ventilator Sensor

Turbine, single stage Electrode + transmitter

1 1

Biological filter Bio filtration material Sand Measurement kit

D650, Collecting arm, multitrack valve BIO GROG, 3/7mm Silica 95/1,7mm Discrete NH4 measurement

A21 A22

A3

A4

FRESH SEAWATER 1

AIR NETWORK

A41 A42

B WATER QUALITY CONTROL B1 TEMPERATURE B11 B12

B2

DISSOLVED OXYGEN

B21 B22

B3

NITROGEN SALTS

B31 B32 B33 B34

B4

1 150 200 ?

EFFLUENT TREATMENT Solution of sodium hypochlorite

B41

1

C SHELLFISH STORAGE C1 STORAGE Baskets Tanks

PVC 600l PALLOX, 6 feet, 3 rollers, PEHD injected

Peristaltic pump Fluorometer

Adjustable flow SEAPOINT

1 1

E11

Central Unit

Waterproof

E12

Screen

Waterproof

E13

Keyboard and mouse

Waterproof

E14

Cd-rom

1 1 1 1

C11 C12

4*3 8

D SHELLFISH FEEDING D1 FEEDING D11 D12 Already bought

E SUPERVISION E1 COMPUTER

E2

ACQUISITION

E21 E22

E3

Data acquisition board Conditioning device

NATIONAL INSTRUMENTS Electronic circuit to design

1 1

Sound alarm Visual alarm

Siren Luminous column

1 1

ALARMS

E31 E32

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230VDC/1phase/50HZ beam 12VDC beam 24VDC beam

F11 F12 F13

F2

DETAILS

QTY

Ventilator, peristaltic pump, pump, UV filter, PC, heater/chiller For sensors For sensors

6 1+ 1+

SECURITY Emergency stop Circuit breaker Differential circuit breaker Indicator LED

F21 F22 F23 F24

F3

DESCRIPTION

1 1 1 1

30mA

SUPPLY AND WORK

F31

Shipment

1

F32

Install

1

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