Pregenesis Protocol — CAPEX Summary
Total Module CAPEX — Consolidated Summary
Pregenesis Protocol — All Modules | Class 2 (±15%) OEM Engineering Release | 2026 USD | AACE International RP 18R-97
AACE International RP 18R-97 — Class 2 (±15%) Estimate Basis
This capital cost estimate is classified as Class 2 (±15%) OEM Engineering Release per AACE International RP 18R-97. Estimating methodology: factored/parametric — equipment costs from budget quotes (minimum 2 OEMs per category), ROM quotes, and published industry benchmarks. Installation and indirect costs applied as percentage multipliers. Accuracy range: −15% to +15% of stated values. All values in 2026 USD.
$19M
Total Low Estimate
$37M
Total High Estimate
±15%
AACE Accuracy
3
Module Groups
RevCon 3
Performance Baseline
400 TPD
Factory Basis
Pregenesis Protocol CAPEX — Module Breakdown (Class 2 ±15%, 2026 USD)
Consolidated CAPEX Register — All Pregenesis Modules
| Module / Line Item | TDS Reference | Low Estimate | High Estimate | Estimate Basis |
|---|---|---|---|---|
| MODULES 0A / 0B / 0C — TISAB, Feedstock Ingest, Dual-Trough System & EASB | ||||
| TISAB building — rigid steel frame, insulated metal panel, 2 lanes (incl. weighbridges, sectional doors, body-up detection, RFID, fire suppression) | TDS-002 §10 | $1.8M | $2.8M | Rigid steel frame + insulated metal panel; 22 ft lanes × 110 ft; 105,000 lb NTEP weighbridges; body-up detection (TISAB-HID-001–004) [Class 2 ±15%] |
| Feedstock Ingest reinforced concrete slab + AR400 push walls + floor drains | TDS-002 §10 | $800K | $1.5M | Reinforced slab + AR400 push walls + floor drains; AACE parametric |
| Trough 1 — RC structure + AR400 liner + head-end opening + AR400 impact wall + wheel guides | TDS-002 §10 | $500K | $1.0M | RC walls, AR400 panels, 12 ft × 6 ft head-end opening with AR400 frame and impact wall, wheel guides; structural fabricator budget quote |
| Trough 1 hydraulic counterweighted drawbridges (2 pairs, 45 ft/section) | TDS-002 §10 | $600K | $1.2M | Custom fabrication; AASHTO HL-93 rated; HPUs included; bridge shortened to 45 ft (head-end opening zone undecked) |
| Trough 1 walking floors (2×) + lift conveyors (2×) + APS head-end capture hoods (DUMP-APS-HE-001/002) | TDS-002 §10 | $750K | $1.5M | Keith or equivalent; AR400 slats; enclosed NFPA belt; APS head-end hoods 1,200 CFM normal / 2,000 CFM peak |
| Trough 2 — RC structure + 316L SS liner + leachate sump + tank + pumps | TDS-002 §10 | $500K | $1.0M | RC walls, 316L SS liner, sump, HDPE tank, duplex pumps; corrosion premium included |
| Trough 2 hydraulic counterweighted drawbridges (2 pairs) + HPUs | TDS-002 §10 | $600K | $1.2M | Same structure as Trough 1 bridges + 316L SS deck + Viton/PTFE seals |
| Trough 2 walking floors (2×, 316L SS) + screw/en-masse conveyors (2×) | TDS-002 §10 | $550K | $1.1M | 316L SS slats; corrosion premium ~15% vs AR400; VFD drives |
| EASB building — rigid steel frame, insulated metal panel, 2 lanes (mirror of TISAB) | TDS-002 §10 | $1.8M | $2.8M | Same specification as TISAB Rev 1; rigid frame, sectional doors, 105,000 lb NTEP weighbridges, body-up detection, RFID [Class 2 ±15%] |
| Thermal cameras + Li-battery detection + SCADA integration | TDS-002 §10 | $80K | $150K | Fixed thermal cameras at TISAB approach; Li-battery screening; SCADA integration |
| E&I, controls, Modular Assembly labor (15% + 15%), contingency (15%) | $2.12M | $4.75M | AACE Class 2 multipliers applied to equipment subtotal | |
| Subtotal — Modules 0A/0B/0C | $10.1M | $20.0M | Class 2 ±15% | CBT-PRE-TDS-002 | 2026 USD | |
| MODULE 0D — Liquid Biosludge Delivery Station (ECN-003) | ||||
| LBS manifold (LBS-MNF-001) — 4-in. tri-clamp 316L SS, 2 simultaneous connections | TDS-002 §5.7 | $45K | $90K | 316L SS tri-clamp manifold; 2 connection points; camlock adapters included |
| Progressive cavity pumps — LBS-PMP-001/002 (duplex, 50% duty) | TDS-002 §5.7 | $80K | $160K | Mono / Seepex equivalent; 316L SS wetted parts; VFD; ATEX Zone 22 |
| DS% analyzer — LBS-ANL-001 (technology OPEN — OER Gate 2) | TDS-002 §5.7 | $25K | $65K | Vibrating fork densitometer, Coriolis, or NIR — pending technology selection (ECN-003-A02) |
| Receiving buffer tank — LBS-TK-001 (requirement OPEN — OER Gate 2) | TDS-002 §5.7 | $0K | $120K | 316L SS tank; $0 low = may not be required pending peak tanker rate analysis (ECN-003-A01) |
| APS capture hood — LBS-VNT-001 (800 CFM normal / 1,400 CFM peak) | TDS-002 §5.7 | $30K | $60K | Dedicated APS capture for H₂S, NH₃, methane; flanged duct ASI-APS-FLG connection |
| Wash station — LBS-WASH-001 + controls + E&I + Modular Assembly | TDS-002 §5.7 | $35K | $70K | Hose connections, wash pad, drain; operator safety station |
| Flow measurement — LBS-FIT-001 + controls integration + SCADA | TDS-002 §5.7 | $20K | $45K | Magnetic or Coriolis flow meter; 316L SS; SCADA totalizer |
| Contingency (15%) + E&I + Modular Assembly | $35K | $90K | AACE Class 2 multipliers | |
| Subtotal — Module 0D | $0.6M | $1.2M | Class 2 ±15% | CBT-PRE-TDS-002 §5.7 | ECN-003 | 2026 USD | |
| MODULE T2 — Trough 2 Processing (Dewatering, Drying, Pulverizing) | ||||
| T2 Lumpbreakers — T2-LBK-001/002 + ASI-ISO-LBK-001 kinetic isolation (2×) | TDS-004 §8 | $320K | $720K | Industrial lumpbreakers; neoprene isolation pads ASI-ISO-LBK-001; 1.5 in. static deflection |
| Decanter centrifuges — T2-DCN-001/002 + polymer conditioning T2-PCM-001 (2×) | TDS-004 §8 | $1.6M | $3.6M | Budget quotes — Alfa Laval, Andritz, GEA; polymer dosing system included; 316L SS scroll |
| Indirect Thermal Dryer (T2-ITD)s — T2-ITD-001/002 (2×, Case 2 post-centrifuge) | TDS-004 §8 | $3.2M | $10.0M | LCI Corp (lcicorp.com); Horizontal D or Vertical CP — model per LCI test center evaluation; steam-heated |
| T2 Pulverizer + pneumatic transfer — T2-PNT-001 | TDS-004 §8 | $500K | $1.2M | Pulverizer to <500 μm; pneumatic transfer to SHRD-EAS/APZ inlet |
| Steam supply header, condensate return, APS connections | TDS-004 §8 | $300K | $700K | Steam tie-in from Regenesis WHSG; condensate return; APS vapor capture connections |
| E&I, controls, SCADA, Modular Assembly, commissioning, contingency (15%) | $2.08M | $5.78M | AACE Class 2 multipliers | |
| Subtotal — Module T2 | $8.0M | $22.0M | Class 2 ±15% | CBT-PRE-TDS-004 | 2026 USD | |
| MODULES 1–7 — Full Shredder Train (SHRD) | ||||
| Tire Pre-Shredders — SHRD-TPS-001/002 (2×) | TDS-003 §12 | $800K | $1.6M | Budget quotes — standard catalog; hook-type rotor; 150–220 kW per unit |
| Primary Shredders — SHRD-SHR-001/002 + ASI-ISO-SHRD-001 kinetic isolation + factory-poured inertia base (2×) | TDS-003 §12 | $2.4M | $4.0M | Budget quotes — Vecoplan VEZ 3200, Lindner Polaris 2800, SSI PRI-MAX; ASI-ISO-SHRD-001 spring-damper mounts + inertia base within ASI scope |
| Hammermills — SHRD-HMR-001/002 + ASI-ISO-HMR-001 kinetic isolation + factory-poured inertia base (2×) | TDS-003 §12 | $1.2M | $2.4M | Budget quotes — Stedman Grand Slam, Metso Lindemann LIS; ASI-ISO-HMR-001 within ASI scope |
| Magnetic Ferrous Separators — SHRD-MFS-001 through -004 (4×) | TDS-003 §12 | $150K | $380K | Budget quotes — Eriez, Bunting Magnetics |
| VRM Ash Pulverizers — SHRD-APZ-001/002 (2×) — OPEN: procurement after EDP-IRL-04 grindability test | TDS-003 §12 | $1.2M | $2.2M | Budget quotes — Gebr. Pfeiffer MPS, Loesche LM series; grindability test required before PO (EDP-IRL-04 OPEN) |
| Rotational Mixer — SHRD-MXR-001/002 (2×) | TDS-003 §12 | $600K | $1.2M | Budget quotes — Readco Kurimoto, BHS-Sonthofen DKXC |
| Regenesis Feed Metering Bins — SHRD-RFB-001/002 + Loss-in-Weight Feeders (2×) | TDS-003 §12 | $400K | $800K | 83-ton capacity each; ±0.5% accuracy; demand signal via ASI-DAT-MOD-TCP |
| Enhancement Admix Storage Silos (2×) + Conveyors SHRD-CV-001–007 (7×) | TDS-003 §12 | $600K | $1.2M | Parametric; silo 125-ton each; CEMA-rated conveyors |
| MCC (2× string), SCADA/Controls, Modular Assembly, commissioning, first-fill spares | $3.2M | $4.0M | Factor estimates: MCC 15%; SCADA/Controls 10%; Assembly 15%; Commissioning 5%; Spares 5% | |
| Contingency (15%) | $1.6M | $2.0M | Applied per AACE Class 2 | |
| Subtotal — Modules 1–7 (Full Shredder Train) | $12.2M | $19.8M | Class 2 ±15% | CBT-PRE-TDS-003 | CBT-EDP-SHRD-001 | 2026 USD | |
| EXCLUDED SCOPE — Covered in Separate Budgets | ||||
| PIMB main dumping floor span — clear-span structural fabric building on reinforced concrete slab | Facility civil budget | $2.5M | $4.5M | Separate facility civil contract; not in Pregenesis module CAPEX. TISAB/EASB rigid frame is within module CAPEX above. |
| APS system — baghouse, fans, main ductwork, product recovery (CBT-APS-TDS-001) | CBT-APS-TDS-001 | $1.8M | $3.5M | Separate APS procurement package; referenced in each TDS APS Interface Register |
| Owner's Engineer, permits, regulatory, insurance | Owner's budget | $450K | $1.0M | Owner cost; not in module CAPEX |
| Water treatment module | Facility water treatment TDS | $500K | $1.5M | Separate module; receives leachate from Trough 2 and condensate from T2 dryer |
| TOTAL — All Pregenesis Protocol Modules (0A/0B/0C + 0D + T2 + 1–7) | $30.9M | $63.0M | Class 2 ±15% | AACE 18R-97 | 2026 USD | |
| All-in TIC (including excluded scope above) | ~$36.1M | ~$73.5M | Reference only — excluded scope at ROM accuracy; see individual TDS for detail | |
Cost Escalation & RevCon Return Context
| Metric | Value | Basis |
|---|---|---|
| Total Pregenesis module CAPEX (mid-point) | ~$47M | Average of low ($30.9M) and high ($63.0M) at Class 2 ±15% — includes 0A/0B/0C, 0D, T2, and Shredder Train 1–7 |
| RevCon 3 annual revenue floor (400 TPD factory) | $150M–$325M/yr | RevCon 3 Valorization Ladder baseline |
| Simple payback — Pregenesis module CAPEX only | <3 months | At RevCon 3 revenue floor; Pregenesis is intake infrastructure only — value creation is in Regenesis + Regenesis MAX |
| CAPEX per TPD capacity (Pregenesis modules) | $47K–$93K / TPD | Based on 400 TPD design throughput; Class 2 ±15% |
How to Read This CAPEX
The Pregenesis module CAPEX covers feedstock intake and preparation only — the physical front-end of the ACM Modular Factory. The manufacturing value creation occurs downstream in the Regenesis Protocol (Total Material Conversion) and Regenesis MAX (OmniCrude™ refining). Pregenesis module CAPEX should be evaluated as intake infrastructure cost, not as the basis for revenue return calculations. Revenue is generated by what happens to the Manufacturing Feedstock after it enters the Regenesis reactor.
CBT-PRE-CAPEX-001 | Rev 1 | April 2026 | PROPRIETARY — CARBOTURA INC.
Class 2 ±15% | AACE International RP 18R-97 | 2026 USD | RevCon 3 Performance Baseline
Class 2 ±15% | AACE International RP 18R-97 | 2026 USD | RevCon 3 Performance Baseline