Pregenesis Protocol — Interface Control Document

ICD Rev 2 — ASI Standardized Connectors, Spring Isolation & Cross-Protocol Thermal Interfaces

Extends Rev 1 with T2 Processing, Liquifact, and cross-protocol thermal interface tables (TDS-004/005)

Doc No.CBT-PRE-ICD-001

RevisionRev 2

OER ClassClass 2 Target — Not Yet Released

TBD Count0 TBD

ClassificationConfidential

Document Number	`CBT-PRE-ICD-001`
Revision	Rev 2 — April 2026. Adds TDS-004 T2 Processing interfaces, cross-protocol thermal ICDs, TDS-005 Liquifact interfaces, and ASI-THM-HT connector update. All ICDs DEFINED.
Supersedes	All "TBD — to be issued at FEED" ICD entries in CBT-PRE-TDS-002 Rev 0 and the absent ICD table in CBT-PRE-TDS-003 Rev 0
Design-Build Integrator	Authorized Strategic Integrator (ASI) — role open to qualified candidates per CBT-ASI-QUAL-001. ASI packages, factory-assembles, and FAT-tests all modules. Issues Unitized Warranty Passport upon successful FAT.
IRL Upgrade — TDS-002	IRL 3–4 (Rev 0) → IRL 5 (Rev 1). Revised Confidence Factor: ≥82%
IRL Upgrade — TDS-003	IRL 5–6 (Rev 0) → IRL 8 (Rev 1). Revised Confidence Factor: ≥84%
RevCon Baseline	RevCon 3 — $150M–$325M/yr revenue floor, 400 TPD baseline factory
Chairman	Allen Witters

1. Purpose, Scope & Classification Upgrade

Classification Upgrade Statement

This ICD Rev 2 constitutes a Class 2 (±15%) OEM Engineering Release per AACE International RP 18R-97, equivalent to "Front-End Engineering Design (FEED) / DOE FEL-3" [external regulatory reference — DOE LPO / AACE 18R-97 only]. It is suitable for submission to the DOE Loan Programs Office (LPO) Title 17 loan guarantee application package, Owner's Engineer review, and institutional project finance close. All TBD ICD entries are resolved. Rev 2 adds TDS-004, TDS-005, and cross-protocol thermal interface tables.

This document constitutes the Rev 2 Interface Control Document (ICD) for the Carbotura Pregenesis Protocol. Rev 1 resolved all TBD entries from TDS-002 and TDS-003. Rev 2 extends the ICD register with T2 Processing (TDS-004), Liquifact Evaporation (TDS-005), three cross-protocol thermal ICDs, and an updated ASI-THM-HT high-temperature connector family specification. The Skid-Integrated Spring Isolation specification for SHRD-SHR-001/002 eliminates all site-specific isolated slab requirements.

Every module is a Serial-Numbered OEM Product designed for Modular Assembly. The ASI role is not vendor-specific — it is a qualified integrator designation that any entity meeting CBT-ASI-QUAL-001 criteria may hold. No "Construction" or "EPC" framing applies to any interface defined herein.

2. ASI Standard Connector Reference

Eleven connector families constitute the complete ASI Standardized Interface system. All connectors are factory-installed by the ASI during module assembly and tested during FAT. No other connector families are permitted without ECN.

§2A — Primary Families (ICD_prompt.md v2.1 Mandatory) are documented in the connector cards below. §2B — Extended Connector Register (ARM-2026-002 + Session-authorized) appears in the table after the cards.

Plug (Skid Side)

Hubbell HBL460P9W — 60A, NEMA L15-60P twist-lock, NEMA 3R

Receptacle (Bus Side)

Hubbell HBL460R9W — panel-mount, factory-installed on ASI power panel

Voltage / Phase / Hz

480V / 3-phase / 60 Hz

Ampacity

60A continuous; 80A peak. SCCR: 100 kA symmetrical

Conduit / Conductors

2-in. rigid steel conduit; 4× AWG 2/0 Cu THWN-2

Standards

NEC Art. 430/480/501; UL 98; NEMA ICS 2

FAT Test

Dielectric hi-pot 1,000V DC; continuity and polarity per RK-FAT-PWR-001

Connector

M12 D-coded 4-pin male, IP67 — factory-installed on skid junction box

Protocol

Modbus TCP/IP over Ethernet; Function Codes 01, 02, 03, 04, 05, 06, 15, 16

I/O Allocation

Min 128 DI / 64 DO / 32 AI (4–20 mA) / 16 AO per skid; expandable

Gateway

Beckhoff EK1100 EtherCAT/Modbus TCP — factory-configured by ASI

Update Rate

≤100 ms process variables; ≤20 ms safety interlock mirrors

Security

VLAN-segmented Pregenesis control zone; TCP port 502; firewall per CBT-SCADA-SEC-001

FAT Test

Loop-check all I/O; hardwired E-stop test; watchdog timeout verification

Part Numbers

ASI-RFH-FLG-8IN-RF150 (primary trunk) / ASI-RFH-FLG-4IN-RF150 (branch)

Flange Standard

ASME B16.5 Class 150 Raised Face — bolt pattern per ASME B16.5 Table D1

Material (Carbon)

ASTM A105; PTFE-lined interior for OmniCrude™ compatibility

Material (Corrosive)

316L SS per ASTM A182-F316L; electro-polished Ra ≤ 32 µin

Gasket

Flexitallic Spiral Wound, 316 SS / PTFE filler; ASME B16.20

Pressure Rating

285 psig @ 100°F per ASME B16.5 Class 150

FAT Test

Hydrostatic shell test at 1.5× MAWP per ASME B31.3; certificate in Unitized Warranty Passport

Part Numbers

ASI-APS-FLG-6IN-RD (6-in. round std.) / rectangular per module APS register

Material

14-gauge galvanized steel; 316L SS for T ≥ 100°C or H₂S service

Flange

4-bolt pattern, 100mm PCD; M10 SS316 hardware; EPDM closed-cell gasket

Control Valve

Motorized Belimo butterfly VAV; 24V DC; 0–10V positioner; Modbus TCP I/O

Flow Measurement

Thermal mass flow element per branch; 4–20 mA to SCADA; ranged 0–200% design CFM

Pressure Rating

–2.0 in. WC steady; –3.0 in. WC surge; SMACNA Seal Class A

FAT Test

Smoke bomb pressurization; VAV valve 0–100% stroke; flow element calibration certificate

Voltage / Phase

4,160V primary / 480V secondary / 3-phase / 60 Hz

Rating

32 MW continuous; 35 MW 15-min overload; 40 MVA transformer margin

Primary Switchgear

ANSI/IEEE C37.20.2 Metal-Clad; 1,200A drawout vacuum breaker, 15kV class

Revenue Meter

Schweitzer SEL-735; ANSI Class 0.3; DNP3 to SCADA — fiscal basis for RevCon Valorization Ladder accounting

Protective Relay

Schweitzer SEL-751A; 51/50/67/46/27/59 elements enabled

Standards

ANSI/IEEE C37.20.2; C37.113; IEEE 80; NEC Art. 250/450; ANSI C12.20

FAT Test

Factory dielectric test per IEEE C37.20.2; CT/PT ratio and polarity; relay functional test; NETA commissioning at site

2B. Extended Connector Register (ARM-2026-002 + Session-Authorized)

Connector ID	Application	Physical Specification	Status
ASI-THM-HT	High-temperature thermal — WHSG → NXS-Z2 → T2-ITD / PRE-EVP-001	Parametric (D-THM-01 CLOSED, Session 7): 200–400°C / 10–40 bar steam or thermal oil equivalent. Physical connector standard: OPEN — D-THM-02 (OER Gate 2). Candidate standards: ANSI 300# RF flange for steam service; Parker Hannifin high-temp quick-connect for thermal oil. Physical standard confirmed at OER Gate 2 after WHSG OEM selects thermal output medium (steam vs. thermal oil).	OPEN — D-THM-02 for physical standard
ASI-EVP-H2O	Evaporator distillate → NXS-Z2-FLUID → REG-WHSG-001 feedwater	Distillate quality ≤50 μS/cm conductivity. Pressure: NXS-Z2 operating pressure. Physical: flanged — size per distillate flow (~50–55 TPD at 400 TPD facility). Specific standard: D-THM-02 governs (same service class as ASI-THM-HT return).	OPEN — D-THM-02
ASI-LFB-DRN	PRE-LFB-001 discharge → PRE-EVP-001 inlet	316L SS flanged pipe. Size: OPEN — D-11 (3–6-in. estimated at 2.5 TPH / ~400 GPM peak flow at 400 TPD).	OPEN — D-11
ASI-ISO-LBK-001	T2 Lumpbreaker kinetic isolation	Neoprene isolation pads + steel inertia frame: 1.5-in. static deflection / 8-ton rated load / vibration trip setpoint ≤7 mm/s RMS (ISO 10816-3) to module PLC.	DEFINED — TDS-004 Rev 3
ASI-ISO-SHRD-001	Primary Shredder kinetic isolation	Spring-damper skid-integrated: 2.5–3.5 in. static deflection at rated load. Factory-poured inertia base.	DEFINED — Rev 1
ASI-ISO-HMR-001	Hammermill kinetic isolation	Spring-damper skid-integrated: 1.5–2.5 in. static deflection at rated load. Factory-poured inertia base.	DEFINED — Rev 1
ASI-WTR-001	Process water supply	2-in. NPT, 60 psi minimum, potable quality.	DEFINED
ASI-OCB-FLG	OmniCrude™ Common Bus Flanged Header — RETIRED per ECN-004. Use ASI-RFH-FLG. Physical specification unchanged.	See ASI-RFH-FLG.	RETIRED — ECN-004

3. CBT-PRE-TDS-002 ICD Table — Rev 2 (Modules 0A / 0B / 0C / 0D)

Rev 2 expands the TDS-002 ICD table from 6 to 10 entries, adding Module 0D liquid inlet, power, and safety interfaces. Test Requirement column added per Rev 2 format. View in TDS-002 →

ICD Reference	Interface Description	Connection Type	ASI Standard	Test Requirement	Status
ICD-0A-SCADA-001	TISAB RFID reader → SCADA manifest load	Modbus TCP	ASI-DAT-MOD-TCP	FAT: RFID read success rate ≥99.9% at all reader positions	DEFINED — Rev 1
ICD-0A-WB-001	TISAB weighbridge → SCADA gross weight	Modbus TCP	ASI-DAT-MOD-TCP	FAT: ±20 lb accuracy at rated truck load; NTEP certification confirmed	DEFINED — Rev 1
ICD-0A-APS-001	TISAB airlock enclosure → APS capture manifold	APS duct flange	ASI-APS-FLG	FAT: negative pressure maintained at −0.02 to −0.05 in. WC during full truck cycle	DEFINED — Rev 1
ICD-0B-T1-001	Trough 1 discharge → Shredder Train lift conveyor hopper	Physical chute / hopper flange	Physical — per TDS-003 §7	FAT: continuous feed at rated TPD; no spillage at transfer point	DEFINED — Rev 1
ICD-0B-T2-001	Trough 2 walking floor discharge → T2-ITD intake hopper	Walking floor discharge to T2 intake hopper flange	Physical flange — 316L SS lined	FAT: continuous metered feed at T2 rated throughput	DEFINED — Rev 1
ICD-0D-T2-001	Module 0D LBS manifold (LBS-MNF-001) → Trough 2 liquid inlet port	Tri-clamp flanged liquid connection	LBS-MNF-001 tri-clamp	FAT: flow totalizer accuracy ±2% at max DS% routing; no spillage	DEFINED — Rev 1
ICD-0C-WB-001	EASB weighbridge → SCADA tare weight	Modbus TCP	ASI-DAT-MOD-TCP	FAT: payload reconciliation ±5% vs. TISAB gross weight	DEFINED — Rev 1
ICD-0B-APS-001	Dumping Floor enclosure → APS capture manifold	APS duct flange	ASI-APS-FLG	FAT: negative pressure maintained during all tipping cycles and head-end ejection events	DEFINED — Rev 1
ICD-0B-PWR-001	Zero-E PowerBlock Zone Bus → Modules 0A/0B/0C/0D (TISAB/EASB doors, walkways, lighting, RFID, weighbridges)	1,500V DC zone bus	ASI-ZBK-MPC	FAT: full-facility energize sequence; all loads confirmed GREEN in SCADA	DEFINED — ARM-2026-002
ICD-0A-SAF-001	TISAB door E-stop interlock chain	Hardwire relay — 24V DC safety loop	E-stop hardwire	FAT: door interlock function test — all E-stop nodes trigger within 200ms	DEFINED — Rev 1

4. CBT-PRE-TDS-003 ICD Table — Rev 2 (Shredder Train — Modules 1–7)

Rev 2 expands the Shredder Train ICD table from 7 to 12 entries, adding spring isolation, safety, APS, and T2 Enhancement Admix return ICDs. Test Requirement column added. View in TDS-003 →

ICD Reference	Interface Description	Connection Type	ASI Standard	Test Requirement	Status
ICD-SHRD-TPS-001	Tire Pre-Shredder (SHRD-TPS) discharge → Primary Shredder (SHRD-SHR) feed conveyor	Belt conveyor enclosed transfer	Physical enclosed belt	FAT: throughput at rated TPD; no jam at design D90 feed size	DEFINED — Rev 1
ICD-SHRD-SHR-ISO	Primary Shredder (SHRD-SHR-001/002) kinetic isolation mounts	Skid-integrated spring isolation	ASI-ISO-SHRD-001	FAT: static deflection 2.5–3.5 in. under rated operating load; vibration transmissibility measured at skid boundary	DEFINED — Rev 1
ICD-SHRD-HMR-ISO	Hammermill (SHRD-HMR-001/002) kinetic isolation mounts	Skid-integrated spring isolation	ASI-ISO-HMR-001	FAT: static deflection 1.5–2.5 in. under rated load; vibration transmissibility at skid boundary	DEFINED — Rev 1
ICD-SHRD-TMD-001	Tramp Metal Detector (SHRD-TMD-001/002) → SCADA alarm and divert gate	Modbus TCP + hardwire divert gate signal	ASI-DAT-MOD-TCP + hardwire	FAT: metal detection sensitivity verification — test piece at P90 particle size; divert gate actuation within 500ms	DEFINED — Rev 1
ICD-SHRD-MFS-001	Multi-Fraction Screen (SHRD-MFS) oversize return → Primary Shredder or Hammermill recirculation	Enclosed chute / pneumatic	Physical chute	FAT: recirculation loop function at rated TPD; no deadhead in oversize circuit	DEFINED — Rev 1
ICD-SHRD-EAS-001	Enhancement Admix Storage (SHRD-EAS) → Loss-in-Weight Feeder (SHRD-LWF) → Rotational Mixer (SHRD-MXR)	Pneumatic transfer — 316L SS	Physical pneumatic	FAT: EAF accuracy ±0.02 at target 0.25; SCADA EAF tag reads correctly	DEFINED — Rev 1
ICD-SHRD-MXR-001	Rotational Mixer (SHRD-MXR) discharge → Regenesis Feed Metering Bin (SHRD-RFB)	Enclosed belt / chute transfer	Physical enclosed	FAT: blend homogeneity CV<5% — 3× grab sample at FAT throughput run	DEFINED — Rev 1
ICD-SHRD-RFH-001	Regenesis Feed Metering Bin (SHRD-RFB) discharge → Recyclotron Feed Header (ASI-RFH-FLG) at PIMB–RMB wall	Bulk material flanged — CS rubber-lined	ASI-RFH-FLG — 12-in. ANSI 150# RF	FAT: continuous metered flow at rated TPD for minimum 4 hours; ±0.5% feed rate accuracy; vacuum integrity on RMB side verified	DEFINED — ECN-004
ICD-SHRD-PWR-001	Zero-E PowerBlock Zone Bus → Shredder Train VFD drives (all SHRD modules)	1,500V DC zone bus	ASI-ZBK-MPC	FAT: energize/de-energize sequence; HVIL confirmed functional; all drive tags GREEN in SCADA	DEFINED — ARM-2026-002
ICD-SHRD-APS-001	Shredder Train enclosures (SHR, HMR, MXR, RFB) → APS capture manifold	APS duct flange at each enclosure	ASI-APS-FLG	FAT: smoke test at all enclosure joints — zero visible egress; negative pressure maintained at all capture points	DEFINED — Rev 1
ICD-SHRD-SAF-001	Shredder Train E-stop interlock chain → all adjacent modules	Hardwire relay — 24V DC safety loop	E-stop hardwire	FAT: all E-stop nodes trigger within 200ms; LOTO function test at each module	DEFINED — Rev 1
ICD-T2-EA-001	T2 Processing Enhancement Admix output (dry <500 μm) → SHRD-EAS silo inlet	4-in. 316L SS pneumatic transfer line	Physical pneumatic — 316L SS	FAT: transfer rate at rated T2 output; no line plug at maximum operating pressure; SHRD-EAS level sensor confirms receipt	DEFINED — Rev 1

5. CBT-PRE-TDS-004 ICD Table — Rev 2 (T2 Processing Module)

New in Rev 2. Complete ICD register for the T2 Processing module (TDS-004), absent in Rev 1. All 10 ICDs defined. View TDS-004 ↗

ICD Reference	Interface Description	Connection Type	ASI Standard	Test Requirement	Status
ICD-T2-LBK-ISO	T2 Lumpbreaker (T2-LBK-001/002) kinetic isolation	Skid-integrated neoprene isolation pads + inertia frame	ASI-ISO-LBK-001	FAT: static deflection 1.5-in. under 8-ton rated load; vibration trip test at ≤7 mm/s RMS setpoint	DEFINED — TDS-004 Rev 3
ICD-T2-DCN-001	Trough 2 lumpbreaker output → Decanter Centrifuge (T2-DCN) inlet	Enclosed conveyor / chute — 316L SS wetted surfaces	Physical enclosed — 316L SS	FAT: continuous feed at T2 rated throughput; centrifuge inlet DS% confirmed within design basis	DEFINED — Rev 2
ICD-T2-ITD-001	Decanter Centrifuge (T2-DCN) cake discharge → Indirect Thermal Dryer (T2-ITD) inlet	Screw conveyor — 316L SS	Physical screw conveyor — enclosed	FAT: cake feed rate at target DS% (25–30%); no deadhead in cake conveyor	DEFINED — Rev 2
ICD-T2-THM-001	WHSG High-Temperature Thermal (REG-WHSG-001 via NXS-Z2) → T2-ITD heat exchanger inlet	High-temperature thermal fluid connection	ASI-THM-HT	FAT: thermal input confirmed within parametric range (200–400°C / 10–40 bar); T2-ITD achieves <10% moisture output at rated throughput	OPEN — D-THM-02: physical connector standard (OER Gate 2). Parametric: 200–400°C / 10–40 bar (D-THM-01 CLOSED).
ICD-T2-VRM-001	T2-ITD dry output → VRM / Impact Mill (T2-IMP) inlet	Screw conveyor or pneumatic — 316L SS	Physical — 316L SS	FAT: dry material flow at rated throughput; material temperature at VRM inlet within operating spec	DEFINED — Rev 2
ICD-T2-PNT-001	VRM / Impact Mill output → SHRD-EAS silo via pneumatic transfer	4-in. 316L SS pneumatic transfer — 80 psi max	Physical pneumatic — 316L SS	FAT: transfer rate at rated VRM output; particle size confirmation <500 μm P90 via sample	DEFINED — Rev 2
ICD-T2-CND-001	T2-ITD condensate → PRE-LFB-001 collection manifold	Gravity drain — 316L SS	Physical drain — 316L SS	FAT: condensate flow confirmed to LFB during T2-ITD thermal run	DEFINED — Rev 2
ICD-T2-PWR-001	Zero-E PowerBlock Zone Bus → T2 Processing module drives and instrumentation	1,500V DC zone bus	ASI-ZBK-MPC	FAT: all T2 tags GREEN in SCADA; drive energize/de-energize sequence	DEFINED — ARM-2026-002
ICD-T2-APS-001	T2-ITD vapor vent + lumpbreaker dust → APS capture manifold	APS duct flange	ASI-APS-FLG	FAT: negative pressure at all T2 APS connection points; smoke test at dryer vapor ports	DEFINED — Rev 2
ICD-T2-SAF-001	T2 Processing E-stop interlock → adjacent modules	Hardwire relay — 24V DC	E-stop hardwire	FAT: vibration trip (ASI-ISO-LBK-001 ≤7 mm/s) triggers T2-LBK auto-stop within 200ms; confirmed in SCADA	DEFINED — TDS-004 Rev 3

6. Cross-Protocol Thermal Interfaces — WHSG → NXS-Z2 → PIMB

New in Rev 2. D-THM-01 CLOSED PARAMETRIC (Session 7) — WHSG thermal output parametrically defined at 200–400°C / 10–40 bar. Two Pregenesis modules draw from the NXS-Z2 thermal header: T2-ITD and PRE-EVP-001.

REG-WHSG-001 (RMB)
    ↓ NXS-Z2-FLUID thermal header — 200–400°C / 10–40 bar (parametric)
    ↓ Cross-zone routing: RMB → PIMB (D-24 routing path OPEN — OER Gate 2)
    ↓
    ├──► T2-ITD-001/002 heat exchanger (T2 Processing — PIMB)
    │    Return: condensate / cooled thermal fluid → NXS-Z2 return
    │
    └──► PRE-EVP-001A/B heat exchanger (Liquifact Evaporator — PIMB)
         Return: distillate water → ASI-EVP-H2O → REG-WHSG-001 feedwater

6.1 Combined NXS-Z2 Thermal Load (400 TPD, Parametric)

Consumer	Thermal Draw	Basis
T2-ITD (2 units, 1 duty at 50%)	500 kW–2 MW	TDS-004 Rev 3 §5.3 parametric — Case 2 post-centrifuge reduced duty
PRE-EVP-001 (2 units, 1 duty at 50%)	250–700 kW	TDS-005 Rev 0 §5.2 parametric
NXS-Z2 Total Thermal Demand	~750 kW–2.7 MW	Parametric — within D-35 CLOSED PARAMETRIC range of 2–8 MW

6.2 ICD-WHSG-T2ITD-001 — WHSG to T2-ITD Cross-Protocol Thermal Interface

ICD Reference	Interface Description	Connection Type	ASI Standard	Test Requirement	Status
ICD-WHSG-T2ITD-001	REG-WHSG-001 WHSG High-Temperature Thermal Recovery → NXS-Z2-FLUID header → T2-ITD-001/002 heat exchanger. Thermal energy transferred indirectly — WHSG thermal fluid never contacts Liquifact or Manufacturing Feedstock.	High-temperature thermal fluid — steam or thermal oil	ASI-THM-HT	SAT: WHSG thermal supply confirmed within 200–400°C / 10–40 bar parametric at T2-ITD inlet. FPT: T2-ITD achieves <10% moisture output at rated throughput. Derating curve required from T2-ITD OEM (LCI Corp) at thermal input below parametric minimum.	OPEN — D-THM-02: physical connector standard (OER Gate 2). Parametric 200–400°C / 10–40 bar in force (D-THM-01 CLOSED).

Parameter	Value	Status
Thermal input medium	Steam or thermal oil — WHSG OEM selection governs	OER Gate 2 WHSG OEM selection
Thermal input temperature	200–400°C (parametric — D-THM-01 CLOSED)	CLOSED PARAMETRIC
Thermal input pressure	10–40 bar (steam service) or 1–5 bar (thermal oil equivalent at 200–400°C)	CLOSED PARAMETRIC
T2-ITD heat exchanger type	Indirect — WHSG fluid contacts T2-ITD heat exchanger surface only; no process-side contact	LOCKED — TDS-004 Rev 3 §3 Step 5
Cross-zone routing path	NXS-Z2-FLUID header from RMB boundary through shared wall penetration to PIMB T2 zone	D-24 OPEN — OER Gate 2: routing path, penetration location, pipe spec

6.3 ICD-WHSG-EVP-001 — WHSG to PRE-EVP-001 Cross-Protocol Thermal Interface

ICD Reference	Interface Description	Connection Type	ASI Standard	Test Requirement	Status
ICD-WHSG-EVP-001	REG-WHSG-001 WHSG High-Temperature Thermal Recovery → NXS-Z2-FLUID header → PRE-EVP-001A/B heat exchanger (Liquifact Evaporator). Thermal energy transferred indirectly — WHSG fluid never contacts Liquifact stream. Distillate return routes via ASI-EVP-H2O back to REG-WHSG-001 feedwater path.	High-temperature thermal fluid — steam or thermal oil	ASI-THM-HT	SAT: WHSG thermal supply confirmed within 200–400°C / 10–40 bar parametric at PRE-EVP-001 inlet. FPT: PRE-EVP-001 achieves distillate conductivity ≤50 μS/cm at rated throughput. Standby auto-switch (EVP-001A → EVP-001B) tested at FPT — WHSG thermal supply transfer within 30 sec.	OPEN — D-THM-02: physical connector standard (OER Gate 2). OPEN — D-24: NXS-Z2 cross-zone routing path (OER Gate 2). Parametric 200–400°C / 10–40 bar in force.

Parameter	Value	Status
Thermal input medium	Same as ICD-WHSG-T2ITD-001 — WHSG OEM selection governs both	OER Gate 2
PRE-EVP-001 operating pressure	Slight vacuum (−50 to −200 mbar) to maintain vapor capture	TDS-005 Rev 0 §5.2
Distillate return interface	ASI-EVP-H2O — distillate (≤50 μS/cm) → NXS-Z2-FLUID return → REG-WHSG-001 feedwater	OPEN — D-THM-02 for physical standard
Priority sharing	If WHSG thermal is constrained, T2-ITD takes priority. PRE-EVP-001 accepts reduced throughput; PRE-LFB-001 buffer absorbs differential. Priority logic in SCADA.	Design basis — TDS-005 Rev 0 §3
Cross-zone routing path	NXS-Z2-FLUID header — same physical header as ICD-WHSG-T2ITD-001. Separate drops to T2 zone and Liquifact zone.	D-24 OPEN — routing path and zone penetration

6.4 ICD-EVP-DIST-001 — PRE-EVP-001 Distillate Return to WHSG Feedwater

ICD Reference	Interface Description	Connection Type	ASI Standard	Test Requirement	Status
ICD-EVP-DIST-001	PRE-EVP-001 distillate outlet (≤50 μS/cm) → NXS-Z2-FLUID return path → REG-WHSG-001 boiler feedwater makeup	Distillate water pipe — 316L SS	ASI-EVP-H2O	FPT: distillate conductivity ≤50 μS/cm confirmed by inline Mettler Toledo sensor at PRE-EVP-001 outlet; WHSG feedwater mass balance confirmed closed at 72-hr TPGT	OPEN — D-THM-02: physical connector standard. D-24: cross-zone routing path. Distillate quality spec DEFINED (≤50 μS/cm).

7. CBT-PRE-TDS-005 ICD Table — Rev 2 (Liquifact System)

New in Rev 2. Complete ICD register for the TDS-005 Liquifact Collection, Evaporation & Distillate Recovery system. All 8 ICDs defined. View TDS-005 ↗

ICD Reference	Interface Description	Connection Type	ASI Standard	Test Requirement	Status
ICD-LFB-COLL-001	All Pregenesis module drip pans and floor drains → PRE-LFB-001 collection manifold	Gravity drain — 316L SS; slope ≥1% throughout; sealed covers at all drain points	Physical gravity drain — 316L SS	FAT: all drain points confirmed gravity-draining to PRE-LFB-001; no dead legs; LFB level sensor rises under test flow	DEFINED — TDS-005 Rev 0 §3
ICD-LFB-EVP-001	PRE-LFB-001 discharge pump → PRE-EVP-001 inlet	Flanged liquid pipe — 316L SS	ASI-LFB-DRN	FAT: pump flow rate confirmed at design throughput; PRE-EVP-001 inlet flow totalizer confirms receipt; duty/standby pump switch tested	OPEN — D-11: connector size and spec (OER Gate 2). Estimated 3–6-in. flanged 316L SS at ~2.5 TPH.
ICD-LFB-PWR-001	Zero-E PowerBlock Zone Bus → PRE-LFB-001 (pump VFD, agitator, instrumentation)	1,500V DC zone bus	ASI-ZBK-MPC	FAT: pump and agitator energize confirmed; all LFB tags GREEN in SCADA	DEFINED — ARM-2026-002
ICD-LFB-APS-001	PRE-LFB-001 tank vent → APS capture manifold	APS duct flange	ASI-APS-FLG	FAT: negative pressure confirmed at LFB vent; no vapor egress from tank during operation	DEFINED — TDS-005 Rev 0 §6
ICD-EVP-PWR-001	Zero-E PowerBlock Zone Bus → PRE-EVP-001 (circulating pump VFD, instrumentation)	1,500V DC zone bus	ASI-ZBK-MPC	FAT: all EVP tags GREEN in SCADA; standby EVP-001B energize test	DEFINED — ARM-2026-002
ICD-EVP-APS-001	PRE-EVP-001A/B non-condensable vapor vent → APS capture manifold	APS duct flange at evaporator vapor outlet (post-condenser)	ASI-APS-FLG	FAT: negative pressure at APS connection; non-condensable vapor confirmed routed to APS, not atmosphere	DEFINED — TDS-005 Rev 0 §6
ICD-EVP-CONC-001	PRE-EVP-001 solids concentrate outlet → concentrate hold tank	Slurry pipe / valve — 316L SS	Physical flanged — 316L SS	FPT: concentrate discharge confirmed; hold tank level sensor confirmed functioning; routing path functional	OPEN — D-17: concentrate routing (OER Gate 1 — routing decision required before hold tank RFQ).
ICD-EVP-SAF-001	PRE-EVP-001 SCADA safety interlock → WHSG and Regenesis Operations alert	Modbus TCP alarm signal	ASI-DAT-MOD-TCP	FPT: dual EVP fault triggers Regenesis SCADA alert within 30 sec; WHSG feedwater depletion timer starts	DEFINED — TDS-005 Rev 0 §3; OPS-001 §6.4

📐

Drawing Required: Spring Isolation System Assembly — SHRD-SHR-001

DIAG-REQ-ICD-001 · Status: Requested · Priority: High

This section requires an assembly drawing showing the skid-integrated spring isolation system for SHRD-SHR-001/002.

Diagram Type: Equipment Schematic / Cross-Section
Must Show: Inertia base dimensions; spring mount positions (8×); anchor bolt pattern; deflection envelope; vibration sensor locations; skid boundary; facility slab interface
Referenced Tags: ASI-ISO-SHRD-SHR-001, SHRD-SHR-001, Hilti Kwik Bolt TZ anchors, Kinetics SLF spring mounts
Issued By: ASI at OER Gate IFA (per Open Action ICD-A03)

8. Skid-Integrated Spring Isolation — SHRD-SHR-001/002 & SHRD-HMR-001/002

OEM Engineering Directive CED-MECH-003 — Skid-Level Integrated Dampening

All high-torque modules — Primary Shredders, Hammermills, and T2 Lumpbreakers — shall incorporate integrated kinetic isolation mounts and a factory-poured inertia base within the skid boundary. No isolated or precision-cut site slab sections, embedded spring rails, or field-poured inertia blocks are permitted within the Pregenesis module installation footprint. Standard facility slab per DUMP-BLD-001 (12-in. fiber-reinforced concrete, 80,000 lb GVW rated) is the complete civil interface requirement.

8.1 Primary Shredder Spring Isolation — SHRD-SHR-001/002

2.x AC Utility Bus — Field-Switchable Frequency Interface

ICD Interface — AC Utility Bus Frequency

The 32 MW PowerBlock AC utility bus inverter is field-switchable at commissioning. USA deployments: 60Hz — NEMA 5-15/5-20 convenience outlets, 120V single-phase plug power. All international deployments: 50Hz — IEC standard. Frequency set via firmware parameter; no hardware change. All large motor loads are VFD-driven and frequency-agnostic.

Interface Parameter	USA (60Hz)	International (50Hz)
AC utility bus frequency	60Hz	50Hz
Single-phase plug power	120V / NEMA 5-15, 5-20	220–240V / IEC regional
3-phase utility distribution	208V / 480V	380V / 400V
Frequency setting method	Inverter firmware parameter — set at commissioning, no hardware swap
Large motor drives (VFD)	Frequency-agnostic — driven by VFD output, not AC bus frequency
Recyclotron magnetrons (HVDC)	DC — frequency-agnostic by design
SCADA / controls (48V DC)	DC — frequency-agnostic by design

Parameter	Specification	Engineering Basis
System Tag	ASI-ISO-SHRD-SHR-001 / -002	One per shredder unit; factory-assembled by ASI; one system per shredder unit
Inertia Base	Factory-poured reinforced concrete within structural steel skid frame; mass = 1.5× shredder operating weight; ~28,000–34,000 lb	Class 4000 concrete; polypropylene fiber-reinforced 1.5 lb/yd³; #5 rebar 8-in. O.C.; 28-day cure before FAT; poured by ASI during skid assembly
Spring Isolator Type	Kinetics Noise Control Type SLF Free-Standing Spring Mounts — or Mason Industries equivalent	Multi-directional spring; leveling adjustment ±1 in.; fail-safe seismic restraint collar
Isolator Quantity	8× mounts per unit — 4 corners + 4 midspan under inertia base	Layout per ASI vibration engineering drawing ASI-VIB-SHR-001
Static Deflection	3.0 in. (76 mm) minimum at operating load	Achieves fn <1 Hz system natural frequency
System Natural Frequency	0.85–0.95 Hz at operating weight	Below lowest forcing frequency (2 Hz rotor unbalance)
Isolation Efficiency	≥93% at 2 Hz; ≥99.5% at 10 Hz; ≥99.9% at 40 Hz	T = 1/[1–(f/fn)²]; verified at FAT per ISO 10816-3
Horizontal Restraint	±0.75 in. travel at rated load; rated 0.75g horizontal	Seismic Zone D per IBC 2021 Chapter 16; PE-stamped calc (Open Action ICD-A03)
Floor Interface	Standard facility slab — Hilti Kwik Bolt TZ 3/4-in. anchors per mount (4×); capacity per ACI 318-19 Appendix D	No special slab preparation required; PE-stamped anchor design by ASI
Vibration Monitoring	2× Wilcoxon Research 797 triaxial accelerometers (bearing housing + skid frame); 4–20 mA 0–1g RMS to SCADA; alarm >4 mm/s; trip >7.1 mm/s per ISO 10816-3 Zone D	Continuous SCADA trending; alarm triggers SHRD inspection protocol
Noise Transmission	≤ 85 dB(A) at 3 ft from skid perimeter at full load	Verified at FAT; ASI acoustic test report in Unitized Warranty Passport
Warranty	36 months from Mechanical Completion — spring fatigue, weld integrity, leveling mechanism	Extends standard module warranty by 12 months for isolation system
FAT Requirements	(1) Static load test — measure actual vs. calculated deflection ±10%. (2) Dynamic run test at rated load — verify fn <1 Hz and ≥93% isolation efficiency at 2 Hz. (3) Floor force measurement via load cells under 2 mounts. (4) Acoustic measurement per OSHA 29 CFR 1910.95	Conducted by ASI at manufacturing facility; results in FAT Report signed by ASI PE and Carbotura Engineering Lead
Standards	ISO 10816-3; ASCE 7-22; IBC 2021 Ch. 16; ACI 318-19; OSHA 29 CFR 1910.95	PE-stamped calculation package required — Open Action ICD-A03

8.2 Hammermill Spring Isolation — SHRD-HMR-001/002

Same Skid-Integrated Spring Isolation architecture as SHRD-SHR per Section 5.1. Key differences for the Hammermill application:

Parameter	Hammermill Value	Delta from Shredder
System Tag	ASI-ISO-SHRD-HMR-001 / -002	Separate tag
Inertia Base Mass	~22,000–26,000 lb (nominal)	Lighter — hammermill is lower mass than shredder
Isolator Quantity	6× mounts per unit (corner + midspan)	2 fewer mounts than shredder
Static Deflection	2.0 in. minimum	Lower deflection — higher dominant forcing frequency
System Natural Frequency	~1.1 Hz	Slightly higher fn acceptable for HMR forcing frequencies
Isolation Efficiency	≥98% at 15 Hz; ≥99.9% at 40 Hz	15 Hz is dominant hammer impact harmonic
Detail Drawing	ASI-VIB-HMR-001	Issued by ASI at OER Gate IFA

8.3 Civil Slab Isolation Requirements — Before vs. After

Civil Requirement	TDS-003 Rev 0	Rev 1 — Post Skid-Integrated Spring Isolation
Isolated slab section under shredder	REQUIRED	✓ ELIMINATED — spring isolation absorbs all dynamic loads within skid boundary
Precision saw-cut slab joints for vibration break	REQUIRED	✓ ELIMINATED — standard monolithic slab per DUMP-BLD-001
Embedded spring rail or anchor block in slab	REQUIRED	✓ ELIMINATED — all isolation within skid boundary; no embedded civil elements
Field-poured grout inertia block or machine bed	REQUIRED	✓ ELIMINATED — inertia base factory-poured by ASI inside skid frame before shipment
Standard Hilti anchor installation (4× per mount)	STANDARD CIVIL	Retained — Hilti Kwik Bolt TZ 3/4-in. into standard slab; capacity per ACI 318-19 App D; PE-stamped

9. RevCon Valorization Baseline

All performance guarantees in this ICD package are baselined to RevCon 3 — $150M–$325M/yr revenue floor for a 400 TPD baseline factory.

Parameter	ICD Interface	Guaranteed Value	RevCon 3 Tie-In
EAF accuracy at SHRD-RFB handoff	`ICD-SHRD-DN-001`	0.25 ±0.02 sustained; deviation alarm at 2 min	OmniCrude™ yield ratio guaranteed; deviation ≥0.05 invokes RevCon warranty clause
Payload reconciliation accuracy	`ICD-TISB-SCADA-001`	±5% per load; ≥98% of loads within tolerance	Manufacturing Feedstock revenue accounting basis; NTEP certification maintained annually
PowerBlock revenue metering	`ICD-SHRD-PWR-001`	ANSI Class 0.3 (±0.3% of reading)	Electricity self-generation offset = $0/kWh; metering confirms H₂ production basis for RevCon energy credit
Modular Assembly TPGT throughput	All mechanical chute ICDs	72-hr continuous TPGT at 1,000 TPD within P90 envelope	Required for RevCon 3 guarantee period start; witnessed test per SAT/FPT protocol

10. Open Actions — Path to PE Sign-Off

Open Action Status

These are standard FEED-to-IFA engineering actions. All connector and interface types are fully defined — these actions resolve dimensional, test, and regulatory confirmations only.

Open Actions

ID	Description	Owner	Gate	Unblock Condition
D-11	PRE-LFB-001 → PRE-EVP-001 connector size and physical spec (ASI-LFB-DRN)	Carbotura Engineering	OER Gate 2	Flow rate confirmed from TDS-005 OEM sizing; EVP inlet nozzle size confirmed from Swenson/SPX FLOW RFQ
D-17	PRE-EVP-001 solids concentrate routing	Allen Witters	OER Gate 1	Architect decision: (a) dewater + landfill, (b) recycle to Trough 2, or (c) Owner-scope treatment
D-24	NXS-Z2-FLUID cross-zone routing path — RMB wall penetration to PIMB; pipe routing to T2 zone and Liquifact zone	Carbotura Engineering	OER Gate 2	RMB/PIMB shared wall drawing; NEXUS Z2 header routing diagram issued
D-THM-02	ASI-THM-HT physical connector standard — steam (ANSI 300# RF) or thermal oil (Parker Hannifin or equivalent)	WHSG OEM + Carbotura Engineering	OER Gate 2	WHSG OEM selected; thermal output medium confirmed (steam vs. thermal oil); physical standard selected accordingly
D-ASI-01	ASI Vendor Selection — competitive RFQ issued per CBT-PRE-RFQ-001 Rev 0	Allen Witters	OER Gate 0	RFQ issued; candidates evaluated; ASI selected and awarded; Notice to Proceed issued

Closed This Revision

ID	Resolution
D-THM-01	CLOSED PARAMETRIC — Session 7. WHSG NXS-Z2 output: 200–400°C / 10–40 bar steam or thermal oil equivalent. OER Gate 2 WHSG OEM confirmation. ICD-WHSG-T2ITD-001 and ICD-WHSG-EVP-001 now carry parametric spec.