DPR: INTEGRATED RECIRCULATORY AQUACULTURE SYSTEM

1. INTRODUCTION
Recirculatory Aquaculture System

A Recirculation/Flow-through system is an enclosed system for fish farming where the water
replacement is only to the extent of loss to evaporation and cleaning. In a Recirculation
System, water is reused or partially exchanged, while a production system that uses water
only once is referred exclusively to as a Flow-through system.

It is an intensive approach (higher densities and more rigorous management) than other
aquaculture production systems. Instead of the traditional method of growing fish outdoors in
open ponds and raceways, this system rears fish in indoor tanks within a “controlled”
environment. Recirculating systems filter and clean the water for recycling back through fish
culture tanks. The technology is based on the use of mechanical and biological filters, and the
method can, in principle, be used for any species grown in aquaculture. New water is added
to the tanks only to make up for splash-out, evaporation, and for that used to flush out waste
materials. The reconditioned water circulates through the system, and no more than 10% of
the total water volume of the system is replaced daily.

In order to compete economically and efficiently use the substantial capital investment in the
recirculation system, the fish farmer needs to grow as much fish as possible in the inbuilt

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capacity. Given the fact that traditional methods of fish farming in India are able to produce
up to 2 - 10 MT of fish per hectare of land and at the same time use more than 20 liters of
water per kg of fish, the Recirculatory Aquaculture System may need 1/8th of a hectare &
1/6th of water and still be able to produce up to 60 MT of fish per year.

2. SYSTEM DESIGN
Recirculation/Flow-through systems are beneficial where only limited water is used for the
removal of fish wastes out of the production system. Passing water through a treatment unit
removes ammonia and other waste products, achieving the same effect as a Flow-through
configuration.

A key to successful recirculation production systems is the use of a cost-effective water

treatment unit to remove solid wastes and oxidize ammonia and nitrite-nitrogen. The
following aspects are crucial for successful recirculation systems in aquaculture:

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Fish Farming Recirculation/Flow-through System

The present recirculation system is designed to handle more than 100 table fish/m³. Each
tank measures 7.65 x 7.65 x 1.5 m with a water capacity of 81.93 m³. The system includes 8
tanks of any configuration. The waste treatment system, biofilter, and other support
components are described in previous sections.

Overall System Layout and Components of RAS Unit

The major work entailed in the proposed system includes the construction of cemented
culture tanks, fabrication of pipelines, power availability, and water treatment facilities.
The design and construction details for the project are mentioned in relevant sections.

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1. Fish Culture Tanks

A unit of 8 tanks is proposed, each measuring 7.65 x 7.65 x 1.5 m. The building materials
include bricks, cement, and sand, which are locally available. Water flows out of tanks under
gravity.

2. Water Source

A bore well with a capacity of 3” delivery is the main source of water supply. Power supply
to run the bore well will be through electricity or a pump set.

3. Water Delivery and Hydraulic Gradients

Water will be channeled to each pond through delivery lines. Water flows from culture tanks
to the treatment plant or discard drain under gravity. The top of the treatment basin or
outflow channel remains lower than the bottom of the culture tanks.

4. Temperature Control System

Water temperature varies with species characteristics. Temperature regulation will be

achieved through poly-house construction for a greenhouse effect or by supplementing with
underground water.

5. Aeration System

Aeration is provided through stone diffusers located at the bottom of each tank. Air is
supplied from pumps mounted above the water level. The air delivery line consists of 1-inch
diameter PVC pipes fitted with ¼-inch flexible tubes connecting to air-stone diffusers.

6. Filtration System

Managing a bio-filter involves regular water quality testing to maintain efficiency. The goal
is to keep the bio-filter stable while minimizing uneaten feed and waste build-up. A healthy
bio-filter has a thin growth of orange-brown bacteria on the surface of the bio-filter
material.

7. Design Parameters

 Production Capacity: 42.70 MT

 Capacity of Each Culture Tank: 81.93 m³
 Total Number of Tanks: 8
 Total Capacity of All Tanks: 655.44 m³

3. KEY HIGHLIGHTS FROM RAS TECHNOLOGY

 Water Efficiency: RAS reduces water consumption by up to 90% compared to
traditional pond culture.

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  High Stocking Density: Supports 50-150 kg/m³ fish density under optimal
conditions.
 Enhanced Biosecurity: Reduces disease risks due to controlled conditions.
 Reduced Land Requirement: Produces up to 60 MT of fish per year on 1/8th
hectare.
 Sustainable Waste Management: Uses biofiltration and mechanical filtration to treat
water.
 IoT Integration: Smart sensors for real-time water quality monitoring.

4. BENEFITS & JUSTIFICATION

 Promotes sustainable fish farming with minimal water usage.
 Supports commercial farming by entrepreneurs with increased private investment.
 Enhances fish production and income generation.
 Creates employment opportunities in aquaculture and allied sectors.
 Contributes to India’s Blue Revolution through sustainable fish farming.
 Reduces environmental impact by recycling up to 90% of water.
 Ensures year-round fish production under controlled conditions.
 Can be adapted for various species such as Pangasius and Tilapia.
 Real-time water monitoring through IoT-based smart sensors.

5. OBJECTIVES
 Establish RAS-based cold-water fisheries in Darbhanga.
 Increase productivity per unit area through advanced aquaculture techniques.
 Ensure a sustainable and high-yield fish production model.
 Encourage the use of modern infrastructure for quality seed rearing.
 Strengthen the local economy through market-driven fish farming.
 Implement IoT-based monitoring to optimize water quality parameters.

6. STRATEGY
 Integrated approach to set up RAS units.
 Increase in fish feed production infrastructure.
 Promotion of indoor culture-based fisheries.
 Cluster approach to be adopted.
 Diversification of cultured species.
 Tie-up of all stages from fish seed to marketing.

7. PROJECT SUMMARY
Title: Establishment of Large RAS for Cold Water Fisheries in Darbhanga, Bihar

Implementing Agency: Private Entrepreneurs

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No. of Units: 1 RAS Unit (8 Tanks)

Unit Cost (Rs. in Lakh):

 Capital Cost: 50 Lakh

Total Project Cost (Rs. in Lakh): 50 Lakh

Central Share (40%): 20 Lakh (under PMMSY)

Beneficiary Share (5%): 2.5 Lakh (Own Contribution)

Bank Finance under CGTMSE: 50 Lakh (95%)

CGTMSE Coverage: 42.5 Lakh (85%)

Subsidy for Women Entrepreneurs: 60% (under PMMSY) 30 lakh

Project Duration: 12 Months

Contact: Suman Jha – 9764186280

8. TECHNICAL DETAILS
a. Site/Location Details

 Location: Darbhanga, Bihar

 Land Requirement: 1/8th of a hectare
 Land Availability: The land for the project will be leased by the beneficiary.
 Water Source: Borewell with regular water availability.
 Power Supply: Uninterrupted power with backup (DG set).
 Road Access: Easily accessible for transportation and logistics.
 Market Access: Proximity to fish markets, hotels, and exporters.

b. Technical Specifications for RAS

Description Quantity Specifications

High-density polyethylene (HDPE) / FRP
90 m³ Circular Fish Tanks 8
material
Biological & Mechanical Filtration Multi-layer biofiltration with activated
1
System carbon
Drum Filter (Automatic) 1 60-micron filter capacity
UV Sterilization System 1 99.9% pathogen elimination
Oxygen Mixing System 1 Fine bubble aeration system
Water Recirculation Pumps 1 1000 LPH capacity

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Aeration & Temperature Control Auto-regulated oxygen and temperature
1
System management
Feed Storage & Processing Unit 1 500 kg storage capacity
IoT-Based Water Monitoring
1 Smart sensors for pH, DO, temperature
System

Additional Infrastructure Details (as per RAS guidelines)

 Tank Dimensions: 7.65m x 7.65m x 1.5m per tank

 Total Water Capacity: 655.44 cubic meters
 Filtration System: Includes biofilters and sedimentation tanks
 Aeration System: Stone diffusers and PVC-based air distribution network
 Temperature Control: Polyhouse covering or groundwater supplementation

9. COST ESTIMATES
Component Cost (INR Lakhs)
Construction of Tanks & Shed 20
Water Filtration & Aeration System 10
Power Backup (DG Set) 5
IoT-Based Water Monitoring 5
Feed, Labor & Maintenance 10
Total Cost 50 Lakhs

10. PROFITABILITY ANALYSIS

Parameter Amount (INR)
Total Revenue (42.70 MT @ ₹164/kg) ₹70,02,800
Operational Costs ₹30,00,000
Feed Cost (FCR 1.2:1, ₹40/kg feed) ₹18,00,000
Seed Cost ₹2,00,000
Labor Cost ₹3,50,000
Electricity & Diesel (Backup power) ₹2,50,000
Maintenance & Miscellaneous ₹4,00,000
Net Profit ₹40,02,800
Return on Investment (ROI) 80%

Key Insights:

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  High ROI (80%) makes this project financially viable.
 Feed cost remains the highest expense, making feed efficiency crucial.
 Diversification of fish species ensures stable revenue streams.
 IoT-based water monitoring optimizes operational efficiency.

11. Time lines

12. Model of RAS 8 Tanks

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LAND REQUIREMENT
Single RAS unit with 8 tanks requires approximately 0.2 to 0.25 hectares (2,000 - 2,500 square
meters)

A single RAS unit with 8 tanks requires approximately 0.2 to 0.25 hectares (2,000 - 2,500
square meters) of land. This includes space for:

 Culture Tanks (8 units, each 7.65m x 7.65m x 1.5m)

 Filtration System and Biofilter Area
 Water Storage and Treatment Facilities
 Pump and Aeration System Setup
 Feed Storage and Processing Unit
 Operational and Management Space

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Appendix:

SPECIES-WISE PRODUCTION AND MARKET PRICE

Species Production Quantity (MT) Average Market Price (₹/kg)

Tilapia 12 ₹160

Pangasius 10 ₹120

Catfish 8 ₹200

Singhi 5 ₹275

Grass Carp 4 ₹170

Common Carp 3.7 ₹150

Total 42.70 MT Weighted Avg: ₹164/kg

Final Results:

 Total Revenue for 32 MT: ₹52,57,745 (52.58 lakh INR)

 Demand-Weighted Average Price: ₹164/kg

Key Insights:

1. Tilapia and Catfish: These species dominate the production and revenue due
to their higher ratios and moderate prices.
2. Singhi: Despite its lower production ratio, Singhi contributes significantly to
revenue due to its high market price.
3. Average Price: The demand-weighted average price of ₹164/kg reflects the
influence of species like Tilapia, Catfish, and Singhi.

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