CBT-FR-PRE-001 — Trough 1 (Main)
Approved by Architect on 2026-07-10 (exchange commit f09c50d) with rulings C-1 (a) split, C-3 (b) Z-03 pending DHA, C-15 ASI internal QA + PE stamp. Source payload inbox/CAFI-pregenesis-trough1-baseline@1.0.0 (sim_hash sha256:ad2ab5…8f6c). Digital Triplet binding is DOCUMENTATION-DERIVED for this mechanical Frame (reactor-coupled Frames CBT-FR-REG-* will carry proper multiphysics bindings).
1. Purpose & Scope
CBT-FR-PRE-001 is the first serialized, FAT-certifiable, warranty-passported Frame in the Pregenesis™ Protocol. It performs mechanical size reduction of unsorted Manufacturing Feedstock (mixed municipal solid stream + end-of-life tires) to <50 mm, recovers ferrous material as a product stream, and meters conditioned feed to the downstream Blend Frame CBT-FR-PRE-003.
The Frame contains no thermal conversion, no chemistry, no gas-phase operations. Mechanical only.
2. Frame Delivery Overview
| Frame ID | CBT-FR-PRE-001 |
| Line (parent) | L-TROUGH1 (Pregenesis Trough 1) |
| Sibling Frame | CBT-FR-PRE-004 (redundant SHRD-SHR-002) |
| Modules contained | M-SHRD-P1 (partition), M-FEMAG-P1, M-WGH-P1 |
| Equipment count | 5 items |
| Shipping mode | ROAD-OPEN-SKID (two-deck rack) |
| Total dry weight | 21,600 kg |
| Installed electrical | 272 kWe |
| Installed thermal | 0 kWth |
| Area classification | Z-03 combustible-dust (pending DHA per C-3) |
| Certifying signatory | ASI internal QA + PE stamp (per C-15) |
3. Line Context
Under D-FME-01 R6 (7-level FMEA hierarchy: Line ⊃ Frame ⊃ Module ⊃ Equipment), CBT-FR-PRE-001 is one of two sibling Frames within Line L-TROUGH1. Sibling: CBT-FR-PRE-004 (redundant primary shredder).
L-TROUGH1 is one of three Pregenesis Lines that feed the Blend Frame:
- L-TROUGH1 → CBT-FR-PRE-001 + CBT-FR-PRE-004 (this Line — MSW + tires size reduction)
- L-TROUGH2 → CBT-FR-PRE-002 (ash + sludge, not yet drafted)
- L-BLEND → CBT-FR-PRE-003 (blend + feed elevator, not yet drafted)
4. Module Composition
| Module ID | Function | Equipment count |
|---|---|---|
| M-SHRD-P1 (partition) | Size Reduction — feed metering, one primary shredder, hammermilling to <50 mm | 3 items |
| M-FEMAG-P1 | Ferrous Recovery — overband magnetic recovery of steel + liberated tire wire | 1 item |
| M-WGH-P1 | Metering — gravimetric weigh-feeder + surge bin to Blend Frame | 1 item |
Second redundant primary shredder (SHRD-SHR-002) is packaged in sibling Frame CBT-FR-PRE-004 per D-FME-01 R1 (envelope split) and Architect Ruling C-1.
5. Equipment Schedule
| Tag | Description | Duty | Dry Weight (kg) | Plan Area (m²) | Electrical (kWe) |
|---|---|---|---|---|---|
| SHRD-FDR-001 | Drag-Chain Trough Feeder | 100 TPD; 7 kW | 3,000 | 24 | 7 |
| SHRD-SHR-001 | Primary Shredder A | 100 TPD @ 50% duty; 160 kW | 9,500 | 16 | 160 |
| SHRD-HMR-001 | Hammermill | 100 TPD; 90 kW | 5,500 | 10 | 90 |
| SHRD-MAG-001 | Overband Ferrous Magnet | 100 TPD; 6 kW | 1,000 | 6 | 6 |
| SHRD-WGH-001 | Weigh-Feeder / Surge Bin | 100 TPD; 9 kW | 2,600 | 12 | 9 |
| Totals | — | — | 21,600 | 68 | 272 |
Design T, P, materials, and L·W·H are all TBD in the payload (mechanical ambient; formal ratings pending detailed engineering).
6. Fit Check
| Constraint | Limit (ROAD-OPEN-SKID single-deck) | Actual | Result |
|---|---|---|---|
| Floor plan area (single deck) | 39.47 m² | 68 m² | 2-DECK REQUIRED |
| Floor plan area (two deck) | 78.94 m² | 68 m² | PASS |
| Gross weight | 36,287 kg | 21,600 kg | PASS |
7. Area Classification & Utilities
Per Architect Ruling C-3 (2026-07-10): dry size-reduction of mixed MSW (paper / film plastics / tire crumb) is a recognized explosible-dust hazard under NFPA 652 / NFPA 654. Z-03 working assumption applied pending formal Dust Hazard Analysis (DHA) at OER Gate 2.
Electrical selection: Class II Div 2 minimum inside the Frame; Class II Div 1 in the immediate vicinity of any equipment producing airborne fines.
| Utility | Demand | Source |
|---|---|---|
| Electrical | 272 kWe installed | Zero-E PowerBlock™ via NEXUS Z1 |
| Thermal | 0 kWth | — |
| Steam | 0 kg/hr | — |
| Instrument air | TBD | NEXUS Z3 |
8. Frame-Boundary Interfaces
| Stream ID | From | To | Phase | Mass Flow (kg/hr) | T (°C) | P (barg) | Connection |
|---|---|---|---|---|---|---|---|
| S-MSW-TIRES-IN | PLANT-INLET | CBT-FR-PRE-001 | solid | TBD | 25 | 0 | mechanical |
| S-FEED-SHR-B-OUT | CBT-FR-PRE-001 | CBT-FR-PRE-004 | solid | TBD | 25 | 0 | mechanical (Y-split feed) |
| S-FEED-SHR-B-IN | CBT-FR-PRE-004 | CBT-FR-PRE-001 | solid | TBD | 25 | 0 | mechanical (return) |
| S-FERROUS-P1 | CBT-FR-PRE-001 | SOLD | solid | TBD | 25 | 0 | mechanical |
| S-FEED-DEFE-P1 | CBT-FR-PRE-001 | CBT-FR-PRE-003 | solid | TBD | 25 | 0 | mechanical |
Mass balance cannot close at this Frame — inbound and outbound mass flows are TBD (100 TPD partition depends on blend recipe, not fabricated).
9. UWP Manifest
Per D-FME-01 R5, the Frame's Unitized Warranty Passport is a nested manifest of Modules and Equipment. Structure:
- Frame certificate — ASI QA lead + PE stamp (per C-15)
- M-SHRD-P1 (partition): SHRD-FDR-001, SHRD-SHR-001, SHRD-HMR-001
- M-FEMAG-P1: SHRD-MAG-001
- M-WGH-P1: SHRD-WGH-001
OEM certificate references and warranty periods are TBD pending OEM selection.
10. FAT Plan Reference
FAT plan document: TBD. Expected scope for a mechanical size-reduction Frame:
- Weigh-in / dimensional check
- Individual equipment functional test
- Frame-level integrated run (FDR → SHR → HMR → MAG → WGH)
- Vibration + noise baseline
- Ferrous-recovery efficiency check (target: >95%)
- Sign-off by ASI QA lead + PE stamp
11. Digital Triplet Binding
This Frame is upstream of the Recyclotron™ multiphysics model and is not bound to a CAFI simulation run. All equipment values are flowsheet nameplate figures sourced from apps/api/scripts/data/reactorTrain.ts, packaged in inbox/CAFI-pregenesis-trough1-baseline@1.0.0/ (sim_hash sha256:ad2ab5…8f6c, verified).
Documentation-derived provenance is doctrinally acceptable for mechanical Frames per D-FME-01. Regenesis™ Frames (CBT-FR-REG-*) will carry proper Digital Triplet bindings.
12. PFMEA Hook
Process FMEA reference: TBD. Placeholder rows (illustrative):
- PF-PRE-001-01: Weld defect on SHRD-SHR-001 rotor mounting → shredder failure
- PF-PRE-001-02: Bearing installation torque out-of-spec → premature bearing failure
- PF-PRE-001-03: SHRD-MAG-001 magnet mounting misalignment → reduced ferrous recovery
- PF-PRE-001-04: SHRD-WGH-001 load-cell calibration drift during transit → metering error
13. MRL Claim
Manufacturing Readiness Level: working self-assessment MRL 6–7 (formal DOE/DOD MRL assessment TBD via Item 6 sourcing).
- Equipment individually: MRL 9 (all six equipment classes commercially proven)
- Frame integration: MRL 6–7 (Frame packaging as serialized, FAT-tested, UWP-warranted unit is Carbotura-specific DFM discipline; not yet demonstrated at production rate)
14. Manufacturing Origin
ASI facility: TBD. Production cell reference: TBD. Expected lead time: TBD.
15. Certification & QMS
Certifying entity: ASI internal QA + PE stamp (per Architect Ruling C-15). QMS framework: ISO 9001 baseline (aspirational IATF 16949). Revisit third-party witness (TÜV / SGS / BV) at OER Gate 2 per Frame class.
16. Risk Register
Frame envelope split. Fit-check fails single-Frame ROAD-OPEN-SKID (68 m² vs 39.47 m² single-deck). Mitigation: two-deck rack ROAD-OPEN-SKID (78.94 m² available), plus separate Frame CBT-FR-PRE-004 for SHRD-SHR-002. Ratified 2026-07-10 (Architect Ruling C-1).
Mass flow partitioning depends on blend recipe. Trough 1 / Trough 2 split of 100 TPD basis pending recipe definition. Mass balance cannot close at Frame boundary until defined. Mitigation: blend recipe authoring; iterate this Frame TDS on Twin follow-on payload.
Operating vs installed electrical draw not characterized. Installed 272 kWe is nameplate; steady-state operating figure lower (shredder at ~50% duty). NEXUS Z1 load-schedule needs operating figure. Mitigation: Twin operating-duty case in follow-on payload version.
Dust hazard analysis pending. Z-03 combustible-dust working assumption applied per C-3; formal DHA (NFPA 652 / NFPA 654) is OER Gate 2 open item. If DHA finds Z-02 or Z-01 required, electrical selection escalates. Mitigation: commission DHA via Item 3 or Item 5 sourcing engagement.
17. Assumptions & TBDs
See draft-v1 §17 for the full 15-item enumerated list. Key items:
- Mass split (S-MSW-TIRES-IN / S-FERROUS-P1 / S-FEED-DEFE-P1): TBD (blend-recipe dependent)
- Equipment L·W·H (mm): TBD (payload gives plan area only)
- Design T·P·materials: TBD (ambient near-atmospheric mechanical Frame)
- Formal DHA: TBD (OER Gate 2)
- Operating vs installed kWe: TBD (follow-on payload)
- Frame-boundary ICDs (5): TBD authoring
- Manufacturing origin (ASI facility): TBD
18. Approval & Iteration Notes
Approval: Rev 0 approved by Architect A. Witters on 2026-07-10 via exchange-repo commit f09c50d with rulings C-1 (a) split, C-3 (b) Z-03 pending DHA, C-15 ASI internal + PE stamp.
Twin acknowledgment: Twin ACKed draft v1 (exchange commit c8a9bea) with no numeric disputes; four conditions (C-1..C-4) raised as architectural items now resolved.
Iteration items for Rev 1: blend recipe (closes R-002), operating-kWe (closes R-003), DHA outcome (closes R-004), sibling-Frame integrated commissioning test results.
Portal-published · CBT-FR-PRE-001 · Rev 0 · Carbotura Inc. · 2026-07-10 · ISC-2 Confidential