Fish Tank Costing
r h
Vtower = π 2tower tower (14)
of towers
Vtank, total = Vtower, total = Vtower × # (15)
CBM, tanks = V
tank
Vtank, total
× CBM, 1 tank (16)
Pump and Motor Costing and Sizing - Inline Centrifugal Pump (Storey)
Qpump= Vtank× 2 circulations1 hour × 10 tanks1 pump (17) hwater = A
tank, total
Vtank, total
(18)
Hpump = htower− hwater (19)
Spump= Qpump× H0.5pump (20)
Determine CBof one pump from Fig. 8 using Spump.
50
Cp = CB × FT × FM (21)
(Seider et al. 452) .5
FT = 1 (22)
(Seider et al. 452)
FM, cast iron = 1 (23)
otal pumps
CBM, pumps = Cp × FBM × t (24)
(Seider et al. 441) .30
FBM, pump = 3 (25)
CBMcorr, pumps = CBM, pumps× II
base (26)
Average CE index 2019 (Jenkins) 07.5
I = 6 (27)
Average CE index 2013 (Seider et al. 452) 67
Ibase = 5 (28)
∑C
CT BM = BM = CBM, tanks+ CBMcorr,pumps+ CBM,tomatoes+ CBM,lettuce+ CBM, strawberries+
+ CBM, solar panels+ CBM, ,lighting + CBM,fish (29)
A.3.2 Direct Permanent Investment Costing
for an Integrated Complex .04C
A.3.3 Total Depreciable Capital Costing
0.18C
Ccont= DP I (35)
C
CT DC = DP I+ Ccont (36)
A.3.4 Total Permanent investment Costing
.02C
51
CT P I = CT DC + Cland+ Croyal + Cstartup (40)
CT P Icorr = CT P I × FISF (41)
; U.S. Southwest (Seider et al. 443) .95
FISF = 0 (42)
A.3.5 Total Capital Investment Costing
CT CI = CT P Icorr0.9 (43)
A.3.6 Working Capital Costing
.1C
CW C = 0 T CI (44)
A.3.7 Cost of Manufacture Excluding Depreciation Operations (O)
W &B shifts
D = operator−hr$40 × 8 operators1 shift × 40 hours1 week × 52 weeks1 year × 2 (45) griculture and F ish Harvesting shifts
A = $19,1401 year × 10 harvesters1 shift × 2 (46)
irect Salaries & Benefits 0.15 W &B
D = × D (47)
perating Supplies & Services 0.06 W &B
O = × D (48)
ontrol Laboratory shifts
C = $65,0001 year × 8 operatorsshift × 2 (49)
Maintenance (M)
W &B 0.045C
M = T DC (50)
for solids-fluids processing .5%
4
alaries & Benefits 0.25 W &B
S = × M (51)
aterials & Services 1 W &B
M = × M (52)
aintenance Overhead 0.05 W &B
M = × M (53)
&O W &B Σ(DW &B, Agriculture and F ish Harvesting, Direct Salaries & Benefits,
M − S =
W &B, Salaries & Benefits)
M (54)
Operating Overhead
52 eneral P lant Overhead 0.071 M&O W &B)
G = × ( − S (55)
echanical Department Services 0.024 W &B
M = × M (56)
mployee Relations Department 0.059 M&O W &B)
E = × ( − S (57)
usiness Services 0.074 M&O W &B)
B = × ( − S (58)
Property Taxes and Insurance
roperty T axes and Insurance 0.02C
P = T DC (59)
A.3.8 Depreciation
epreciation 0.08 (C .18C )
D = T DC− 1 alloc (60)
A.3.9 Cash Flow Analysis
C
f T DC = Y ears to buildCT DC (61)
Y ears to build = 1 (Annual Supply rice)
S = Σ × P (62)
et Earnings S )(1 )
N = ( − Cexcl.Dep− D − t (63)
net earnings ) C
C = ( + D − f T DC − CW C − Cland− Cstartup− Croyal (64) isc. Cash F low (P V ) ( )
D = (1+i)1 n * C (65)
um P V Cum P V )
C n = n−1+ ((1+i)1 n * C (66)
53 Appendix B. SpreadSheets with Explanations
Dimensions for Foothills Mall in Tucson, AZ used in size calculations, and customer information for Tucson, AZ. Information about plants and fruit production, and yearly production
calculations (Appendix A.1). Initial size optimization for towers and shelves.
54
Parameters and calculations for the number of towers needed, and the area needed for the towers as well as bare module costs of towers.
55
Total area used by components of the vertical farm and scale up factor production increased by.
The vertical farm was scaled up to fill the facility as seen by the current scale up factor of about 1.
56
Fish tank nutrients (TAN) and water flow rate calculations. Nutrient requirements by plant and daily flow rate of nutrients to towers (specific calculations seen Appendix A.2).
57
The nutrient production rates were used to calculate the number of necessary fish as well as the cost of the fish. The utilities were calculated per the Tucson rates, the lighting needed for the facility was calculated as well as the bare module cost, and the number of fish tanks were calculated.
58
The pump sizing was performed using Seider et al.
59
The water requirements were calculated based on the tower specifications (Faircloth).
Additionally, the nutrient efficiency was assumed to 0.8 as suggested by the mentor.
The mass balance and water usage are shown. The mass balance calculations are shown in Appendix A.2.
60 Appendix C. Mass Balance (from Subunit PFD) and Energy Balance
Stream Table 9a: Mass Balance from Streams 1-10 for Process Subunit
Stream Table 9b: Mass Balance from Streams 11-23 for Process Subunit
61
Table 10: Energy Demand from NREL solar calculator (Dobos).
62 Appendix D. Supplemental Figures and Information from the Web
Figure 7: PFD detailing the overall process design of the vertical farm
Figure 8: Base free on board (f.o.b.) purchase cost for radial centrifugal pumps (Seider et al. 452).
63
Figure 9: Layout of a vertical farm simulated in Berlin, Germany designed in a CE Study by the author at DLR Bremen (Banjeree and Adenaeuer). This model was used for inspiration when deciding the proportions of produce
for Foothills Mall.
64 Appendix E. Hazards and Operability Reviews (Using Fig. 7)
Project Name: Sustainable Vertical Farming Using Abandoned Malls Date: 4/10/20 Page 1 of 2 Process Equipment (PFD #): Fish tank (V-101) Name of Individual Doing Review: Martin Inostroza
Section: Reference Drawing: PFD
Study Node Process Parameters
Deviations (Guide Words)
Possible Causes Possible Consequences Include info on process immediately downstream
Action Required
Fish tank Temperature
Water Flow Rate
Ammonia Concentration
Too low Heater stopped working. Reduced fish growth rate.
Fish could catch a disease.
Have an external heater to keep the temperature at the right range.
Too high Temperature was left high on the heater.
Ambient temperature increased.
Breeding rate increases.
Fish could die due to hot water.
Add cold water to the tanks while releasing the hot water.
Too low There is a leak on the pipe. There is not enough water in the fish tank for the fish to all be submerged in the water.
Have an extra water tank with a valve that opens when the fish tank height gets too low.
Too high City water valve is broken thus the water coming in is not controlled.
Fish tank overflows.
Fish jump out of the fish tanks, causing fish to possibly die.
Have a valve that opens at the bottom of the fish tank that sends the extra water to the sewers.
Too low Not enough fish in the tank. There are not enough nutrients going into the plants.
Having an extra tank of nitrogen that helps maintain the necessary amount of nitrogen if there is not enough.
Too high There is no water coming in through the city.
Fish tanks can potentially reach 1ppm of ammonia which would cause the fish to die.
Have a backup water tank for the concentration to stay at a good range for the fish.
65
Project Name: Sustainable Vertical Farming Using Abandoned Malls Date: 4/10/20 Page 2 of 2 Process Equipment (PFD #): Fish tank (V-101) Name of Individual Doing Review: Martin Inostroza
Section: Reference Drawing: PFD
Study Node Process Parameters
Deviations (Guide Words)
Possible Causes Possible Consequences Include info on process immediately downstream
Action Required
pH Too low Over time, the pH levels will decrease due to the fish needing the oxygen in the water.
Can damage the fish’s skin which could lead to death.
Fish eggs will not hatch.
There will be a higher concentration of ammonium.
Have aeration systems for the fish tanks to prevent the oxygen levels from dropping too low.
Too high Water coming in has too much oxygen in comparison to the water in the fish tank.
Higher ammonia concentration which will cause the fish to die.
Perform partial water change every once in a while to remove leftover fish waste and fish food.
66
Project Name: Sustainable Vertical Farming Using Abandoned Malls Date: 4/10/20 Page 1 of 1 Process Equipment (PFD #): Vertical Grow Towers (V-102/3/4) Name of Individual Doing Review: Benjamin Martinez
Section: Reference Drawing:
Study Node Process Parameters
Deviations (Guide Words)
Possible Causes Possible Consequences Include info on process immediately downstream
Action Required
Tower Growing Beds
Temperature Too High Improper regulation of ambient temperature, pump inefficiency causing heating of water
Decreased growth rates and potential death of plants.
Higher water consumption from plant
Increased water flow rates and correction of ambient temps
Too Low Improper regulation of ambient temperature
Browning of plant leaves and potential loss of product
Increase intensity of lighting until ambient temperature is corrected
pH Too High Age of plants cause higher nutrient uptake
Decreased growth of plant and size of harvestable product from plant
Increase flow rate through tower to replace diluted water
Too Low Buildup of nutrients due to solids collecting on media
Burning of plant roots and potential loss of product
Cleaning or replacement of media
Pressure Too High Failure of auto shut off valve Plants pushed out of pots in tower, loss of product
Decrease flow rate from pump, monitor pressure gauges
Too Low Failure of auto shut off valve to reopen
Water does not travel to top of tower and plants do not get nutrient
Check pressure for fluid on top of tower while harvesting
67
Project Name: Sustainable Vertical Farming Using Abandoned Malls Date: 04/13/20 Page 1 of 3 Process Equipment (PFD #): Inline Centrifugal Pump (P-101) Name of Individual Doing Review: Kaitlyn Molloy
Section: Reference Drawing: PFD
Study Node Process Parameters
Deviations (Guide Words)
Possible Causes Possible Consequences Include info on process immediately downstream
Action Required
Centrifugal Pump
Temperature Too High High ambient temperature Rubbing of rotating components with a fixed component.
Operation at very low flow.
Increasing pressure in pump Vaporizing liquid
The temperature increase can cause cavitation vibrations, which will damage the internal pump.
Water that is too hot leaving the pump will damage the roots of the crops, and it will cause stress.
The high temperature and increasing pressure risk an explosion in the pump gasket and can damage bearings.
The increasing pressure that causes the high temperature can cause the vaporizing liquid, which can cause an explosion and fire, and the nutrient concentration would become inadequate for the plants.
The rubbing of rotating components with a fixed component can cause damage to bearings.
The pump must be cooled with water generally (pump is inline and is not submerged) Check the pressure in the pump
Open and clean the pump Check the engine rpms Reduce or stop flow rate of water if temperature is too high until pump can cool down
Check the ambient
temperature (vertical farm is in temperature-controlled setting)
Monitor temperature in fish tank
Too Low Operating fault
Abnormally low ambient temperature
Low flow rates Low engine rotations
Water that is too cold leaving the pump will damage the roots of the crops, and it will cause stress.
The low temperature can cause low engine rotations can cause not enough nutrient-enriched water to flow, which will reduce harvest and vegetable production.
Check the engine rotations Increase flow rate if temperature is too low Monitor temperature in fish tank
Check the ambient
temperature (vertical farm is in temperature-controlled setting)
Pressure Too High Blockage in outlet valve Faulty pressure sensor
A pump with too high of a pressure will cause an explosion.
Check and drain the pipes and drain the system
68
Vaporizing liquid Operating fault Increased temperature
A blockage will prevent nutrient-enriched water from entering the grow beds, which will reduce harvest and production of vegetables.
Replace gasket and check the damage
Check pressure with manometer, and replace pressure sensor if necessary Check temperature of fish tank
Too Low Suction valve is closed Operating fault Faulty pressure sensor
A pump with not enough pressure will have cavitation.
This causes a vibration, which damages the internal pump and lowers the flow.
The low pressure will cause a low flow rate, which means the plants will not get enough nutrients, which will affect production or sales.
Check and drain the pipes and drain the system
Check NPSHA>NPSHR Check pressure with manometer, and replace pressure sensor if necessary
None Suction valve is closed Operating fault Pump failure Power outage Motor failure Faulty pressure sensor
Power outage or failures will completely halt production and will affect harvesting.
The pump and production will completely stop without pressure.
No pressure will cause a vibration, which will cause destruction of the internal pump, and cavitation will form to cause further damage.
Check and drain the pipes and drain the system
Check NPSHA>NPSHR Check motor and pump Check pressure with manometer, and replace pressure sensor if necessary Stop production with power outage
Flow Too High High rotational speed; too high engine power
Blockage of outlet valve Operating fault
Controller malfunction
A pump operating at too high of a flow rate will overheat from the engine power and cause a vibration
The vibration will cause destruction of the internal pump, and cavitation will form to cause further damage.
A high flow rate could damage the roots of the plants and affect harvest and production.
Check and decrease rotational speed
Check for blockages
Check composition of the fish tank to make sure it does not affect liquid density enough the pump cannot handle, or that it’s not too much for the fish or plants
Too Low/
None
Low rotational speed Failure at outlet valve Blockage at fish tank
Pump/pipes not fully purged, so there is a blockage, or there is a formation of pockets
A pump operating at lower capacity than design limits can cause recirculation within the pump, which can cause surging and cavitation. Cavitation can then cause erosion of the material, vibrations, noise, and efficiency loss.
Check and increase rotational speed
Check and drain the system Check for blockages directly after the fish tanks, all streams leading to pump
69
Operating fault Controller malfunction
A low flow rate also causes a temperature increase, which causes a vibration. The vibration will cause destruction of the internal pump.
A low flow rate will cause plants to not get enough nutrients, and it will affect production and harvest.
The pump running dry can cause seal failure as well.
Check composition of the fish tank to make sure it does not affect liquid density enough the pump cannot handle Controlling the temperature can prevent the seal from failing
pH Too High Abnormally high concentration of ammonia
Carbonate buildup in system
The water from the fish tank has too much ammonia, so the tilapia will die of ammonia poisoning.
Too much ammonia can reduce the production of vegetables and damage harvest if not caught early on. It can damage plant’s nutrient absorption. The plants need the ammonium concentration as a nutrient.
The high pH can cause corrosion of the internal pump depending on material.
Monitor pH and concentration in fish tank
Check pure water flow rate and pH entering fish tank, and increase flow rate if less alkaline (send water going through system to waste) Check streams and nutrient absorption of plants
Add nitrifying bacteria slowly to oxidize the ammonia to lower pH without chemicals (can also add phosphoric acid safely and effectively) Invest in RO filter if water is hard
Too Low Abnormally high concentration of ammonium
Nitrification process turning fish waste to plant food
Too much ammonium can reduce the production of vegetables and damage harvest if not caught early on. It can damage plant’s nutrient absorption. They will have too many nutrients.
The high pH can cause corrosion of the internal pump depending on material.
Monitor pH and concentration in fish tank
Add calcium carbonate and potassium carbonate to the fish tank to raise alkalinity Check fish and nitrifying bacteria
70 Appendix F. Vendor Emails
71
72 Appendix G. Meeting Minutes
Meeting 1