Pregenesis Protocol — Operational Procedure
Dumping Floor, Trough Feed System
& Exit Airlock Scale Building
Modules 0A (TISAB), 0B (Dumping Floor & Troughs), 0C (EASB) — Complete feedstock intake operations
Document Control
| Document Number | CBT-PRE-OPS-002 |
| Revision | Rev 0 — April 2026 |
| Status | Issued for Review |
| Parent Protocol | CBT-PRE-OPS-001 (Master Operational Protocol) |
| Related Documents | CBT-PRE-TDS-002 (technical basis) · CBT-PRE-OPS-003 (downstream Shredder Train) · CBT-PRE-OPS-004 (Trough 2 Processing) |
| Chairman | Allen Witters |
Manufacturing Classification Notice
All material received and handled within the boundary of this protocol is classified as Manufacturing Feedstock — an input material for Carbotura Advanced Circular Manufacturing. No waste treatment, storage, or disposal activities are defined or implied.Table of Contents
- Purpose & Scope
- Definitions
- Pre-Operation Checklist
- Truck Routing Protocol
- Airlock Door Interlock State Machine
- Tipping Floor Operations
- Trough 1 Operations — Manufacturing Feedstock & Tires
- Trough 2 Operations — Sludge & Ash
- EASB Exit Protocol
- Negative Pressure Management
- Li-Battery & Energetic Material Protocol
- Startup Sequence
- Shutdown Sequence
- Emergency Procedures
- Performance KPIs
1. Purpose & Scope
This protocol governs all operational procedures for the Pregenesis feedstock intake, receiving, and trough feed system — from truck arrival at TISAB through Manufacturing Feedstock delivery to the Shredder Train (CBT-PRE-OPS-003) and Trough 2 Processing (CBT-PRE-OPS-004). It covers Modules 0A (TISAB), 0B (Dumping Floor and Troughs), and 0C (EASB).
| Boundary | Description |
|---|---|
| Upstream | TISAB entry gate (truck arrival from public road) |
| Downstream (Trough 1) | Trough 1 lift conveyor discharge to Shredder Train — governed by CBT-PRE-OPS-003 |
| Downstream (Trough 2) | Trough 2 walking floor discharge to T2 Processing — governed by CBT-PRE-OPS-004 |
2. Definitions
| Term | Definition |
|---|---|
| TISAB | Truck Intake and Scale Airlock Building — Module 0A. Entry pressure boundary and weighing station. |
| EASB | Exit Airlock Scale Building — Module 0C. Exit pressure boundary and tare weight confirmation station. |
| Airlock Sequence | Controlled door interlock cycle that maintains negative pressure boundary during truck transit. |
| Airlock Hold | Dwell period within the airlock where pressure equalization occurs, weight is captured, and load acceptance is confirmed. |
| Drawbridge | Hydraulically actuated bridge section over each trough that raises 45–70° to allow truck tipping. |
| Walking Floor | Reciprocating slat conveyor at trough bottom. Moves Manufacturing Feedstock toward discharge at SCADA-controlled rate. |
| Tare Reconciliation | SCADA comparison of TISAB gross weight to EASB tare weight to confirm net payload delivered. |
| Quarantine Bay QA-01 | Reinforced concrete quarantine pit with water deluge for isolation of energetic or thermal hazard materials. |
| Manufacturing Feedstock | All input material received at the Pregenesis Dumping Floor. Processed as manufacturing input under Carbotura ACM operations. |
3. Pre-Operation Checklist
Mandatory First Step
Do not authorize truck intake or start any equipment until APS is confirmed running and negative pressure is confirmed in the Dumping Floor zone (–0.05 to –0.10 in. WC). This is non-negotiable.Pre-Operation Checklist — All items must be confirmed before authorizing intake
APS running and negative pressure confirmed (–0.05 to –0.10 in. WC in Dumping Floor)
MANDATORY FIRST — do not proceed if failed
TISAB/EASB door controls enabled — both Lane A and Lane B
All 4 bridge hydraulic power units pressure confirmed on SCADA
All drawbridges DOWN and latched — confirm via position sensors (Trough 1A, 1B, 2A, 2B)
Walking floor systems on STANDBY — Trough 1 and Trough 2
Lift conveyors on STANDBY — Trough 1 lift conveyor
Leachate sump pump on AUTO — Trough 2 sump pump
Magnetic head pulley operational on lift conveyor — confirm running prior to conveyor start
Thermal detection camera active (Li-battery detection at TISAB approach)
MANDATORY — do not accept loads without active thermal screening
Bay assignment system and LED signage active — test bay assignment display
SCADA truck routing system active — manifest loading confirmed
Ferrous collection bins FCB-001/002 below HIGH alarm — empty if near HIGH
4. Truck Routing Protocol
4.1 Manifest-Based Lane and Bay Assignment
| Material Type | Trough Assignment | Bay Assignment Logic |
|---|---|---|
| Manufacturing Feedstock (MSW) | Trough 1 | SCADA assigns specific bay for even distribution |
| Sludge or Ash | Trough 2 | SCADA assigns bay based on trough level and NIR zone |
| Mixed | Per programmed split ratio | SCADA assigns partial loads per trough demand |
| PROHIBITED | Divert — do not enter | Truck diverted at entry gate before any door opens |
4.2 Normal Intake Sequence
Truck arrives at facility gate — transponder or RFID reads manifest. Bay assignment pre-loaded.
Traffic control assigns Lane A or Lane B. Entry door status check: entry door OPEN, exit door CLOSED and SEALED.
Truck advances onto scale pit — entry door closes and seals behind truck.
AIRLOCK HOLD: 15-second pressure equalization cycle. TISAB fans balance to –0.02 to –0.05 in. WC relative to outside. Do not open exit door until equalization complete.
Gross weight measured ±20 lb, tare subtracted, net payload calculated and logged to SCADA.
Load acceptance check: manifest match confirmed, weight within range, no prohibited materials flag.
Exit door opens — truck advances onto Dumping Floor. Exit door closes behind truck — lane reset initiated.
SCADA displays bay assignment on LED signage. Truck drives to assigned bay and tips load.
Empty truck drives toward EASB for exit via Section 9 protocol.
5. Airlock Door Interlock State Machine
State Machine Scope
The following 8-state machine (STATE 0 through STATE 7) governs all TISAB and EASB door operations. No door movement is permitted outside this state machine logic. This applies to both Lane A and Lane B independently.| State | Description | Entry Condition | Exit Condition | Action Permitted |
|---|---|---|---|---|
| STATE 0 | Both doors closed — standby | Default on power-up or lane reset | Raise request + all interlocks clear | None |
| STATE 1 | Entry door opening | All interlocks confirmed clear | Entry door fully open confirmed by sensor | Truck enters |
| STATE 2 | Truck entering — on scale | Entry door fully open | Truck confirmed on scale (axle sensors) | Hold — no door movement |
| STATE 3 | Entry door closing | Truck on scale confirmed | Door closed and sealed (seal sensor) | Weighing begins |
| STATE 4 | AIRLOCK HOLD | Entry door sealed | Pressure equalized + weight captured + acceptance confirmed | Weighing and pressure monitoring |
| STATE 5 | Exit door opening | Entry door sealed + load acceptance approved | Exit door fully open confirmed | Truck exits to Dumping Floor |
| STATE 6 | Truck exiting | Exit door fully open | Truck clear + dump body DOWN confirmed | Hold — no door movement |
| STATE 7 | Exit door closing — lane reset | Truck clear + body DOWN confirmed | Exit door closed and sealed | Prepare for next truck → STATE 0 |
6. Tipping Floor Operations
6.1 Truck Positioning and Bridge Raise Sequence
Truck enters Dumping Floor from TISAB exit door. SCADA LED signage displays assigned bay position.
Truck advances to assigned bay — wheel guide rails prevent trough over-run. Truck stops — wheel chock sensors confirm truck stationary.
Bridge interlock check (automatic): adjacent bridge DOWN confirmed, no personnel in proximity zone, truck stationary, hydraulic pressure nominal.
Hydraulic bridge raises to dump angle (45–70°, 60° nominal) — target <60 seconds.
Truck tips load — Manufacturing Feedstock falls into trough. Bridge remains raised while tipping is active.
Truck raises dump body — body-down sensor must confirm body DOWN and latched before bridge lower is permitted.
Bridge lowers — target <60 seconds — bridge confirmed DOWN and latched. Truck drives forward toward EASB.
6.2 Bridge Safety Interlock State Machine
| State | Name | Entry Condition | Exit Condition |
|---|---|---|---|
| B0 | Bridge DOWN / Locked | Power-up default or bridge lower confirmed | Raise request + all interlocks clear |
| B1 | Interlock Check | Raise request received | All interlock conditions confirmed clear |
| B2 | Bridge Raising | All interlocks cleared | Bridge at full dump angle confirmed |
| B3 | Bridge UP / Tipping Active | Bridge at dump angle | Truck body DOWN + load complete + lower request |
| B4 | Bridge Lowering | Lower request + body DOWN confirmed | Bridge DOWN and latched confirmed |
| B5 | FAULT / Locked | Any interlock violation or sensor fault | Supervisor reset + fault cleared + manual confirmation. LOTO required for access. |
Two-Bridge Operation Rule — No Override
Only ONE bridge per trough may be raised at any time. This rule has no override. Raising both bridges on the same trough simultaneously is a hard interlock — prohibited regardless of load conditions. Both troughs may be active simultaneously (e.g., Trough 1 Bridge A raising while Trough 2 Bridge B is lowering is permitted).7. Trough 1 Operations — Manufacturing Feedstock & Tires
7.1 Trough Level Response
| Level Condition | Action | Notification |
|---|---|---|
| HIGH (>80%) | Pause Trough 1 truck intake — hold new deliveries | Alert operations and dispatch |
| NORMAL (20–80%) | Normal operation | None required |
| LOW (<20%) | Increase walking floor speed — request additional truck routing | Alert dispatch |
| LOW-LOW (<5%) | Shredder Train notified of low feed — prepare for feed interruption | Alert OPS-003 operator immediately |
Tire Handling: Whole tires must be tipped at the designated tire bay only — the first 50 ft of Trough 1 (solid-plate bridge section). Crumb rubber and pre-shredded tire material require no special handling and may be tipped at any Trough 1 bay.
APS Rule: If APS capture is lost, tipping operations for Trough 1 must stop immediately. No atmospheric venting is permitted under any operating condition.
8. Trough 2 Operations — Sludge & Ash
8.1 NIR Moisture Routing Logic
| NIR Reading | Material Class | Primary Route | Process Path |
|---|---|---|---|
| <15% | Ash | Bypass dryer | Lumpbreaker → Ash Pulverizer |
| 15–30% | Ash | Dryer trim cycle | Lumpbreaker → Ash Pulverizer |
| >30% | Ash | Full dryer cycle | Lumpbreaker → Ash Pulverizer |
| <15% | Sludge | Flag anomalous — supervisor review | Ash Path (likely dried cake) |
| 15–60% | Sludge | Pre-dewatering → Dryer | Sludge Pulverizer |
| >60% | Sludge | Pre-dewatering MANDATORY | Sludge Pulverizer |
8.2 Leachate Management
| Condition | Action | Next Step |
|---|---|---|
| Normal level | Sump pump AUTO — no intervention | Log volume per shift |
| HIGH alarm | Reduce sludge intake rate — increase pump rate | Monitor until HIGH cleared |
| HIGH-HIGH alarm | Stop Trough 2 intake immediately | Supervisor notification — do not resume until sump capacity confirmed |
⚠ LOCKOUT / TAGOUT REQUIRED — Trough 2 Wash-Down
LOTO required on Trough 2 walking floor and all Trough 2 feed conveyors before any personnel entry into the trough area for wash-down or maintenance.
Confirm zero energy state on all drives before entry. All wash water to leachate collection tank — zero floor discharge.
Zero-discharge policy: no leachate, wash water, or centrate may be discharged to drain or ground under any condition.
9. EASB Exit Protocol
9.1 Normal Exit Sequence
Empty truck drives from Dumping Floor toward EASB. Traffic signal assigns Lane A or Lane B.
Entry door opens, truck advances onto EASB scale — entry door closes and seals. AIRLOCK HOLD: 15-second pressure equalization.
Tare weight measured ±20 lb and logged to SCADA.
SCADA tare reconciliation: EASB tare vs TISAB gross = net payload confirmed. Within ±5% = ACCEPT. Outside tolerance = FLAG for supervisor review.
Exit door opens — truck exits to public road. Exit door closes — lane reset. Load record closed with full timestamps.
9.2 Reconciliation Discrepancy Protocol
| Condition | SCADA Action | Operator Action |
|---|---|---|
| Within ±5% | ACCEPT — record closed automatically | None required |
| Outside ±5% (first occurrence) | FLAG — load record held open — supervisor alert | Investigate cause — document resolution |
| Scale drift suspected | Flag for calibration check | Remove scale from service pending calibration |
| Partial tip confirmed | Adjust delivered tonnage in manifest record | Document and notify dispatch |
10. Negative Pressure Management
| Zone | Normal Setpoint | Alarm Low | Alarm High | Action if Out of Range |
|---|---|---|---|---|
| Dumping Floor (0B) | –0.05 to –0.10 in. WC | –0.03 in. WC | –0.15 in. WC | Alert APS — adjust extraction rate |
| TISAB Airlock (0A) | –0.02 to –0.05 in. WC (during hold) | –0.01 in. WC | –0.10 in. WC | Hold truck — do not open exit door |
| EASB Airlock (0C) | –0.02 to –0.05 in. WC (during hold) | –0.01 in. WC | –0.10 in. WC | Hold truck — do not open exit door |
| Trough 1 (below floor) | –0.05 to –0.10 in. WC | –0.03 in. WC | –0.15 in. WC | Alert APS — check Trough 1 APS damper |
| Trough 2 (below floor) | –0.05 to –0.10 in. WC | –0.03 in. WC | –0.15 in. WC | Alert APS — check Trough 2 APS damper |
Pressure Fault During Tipping — Stop Tipping Immediately
If Dumping Floor or trough zone pressure rises above –0.03 in. WC while any bridge is raised: (1) SCADA auto-issues bridge lower command. (2) Operator confirms bridge lower — do not wait for auto-confirm. (3) Pause all truck tipping in affected zone. (4) Investigate APS fault before resuming. Do not resume tipping until APS confirmation that negative pressure is restored to setpoint.11. Li-Battery & Energetic Material Protocol
11.1 Detection and Quarantine Sequence
Thermal camera triggers on object above 80°C — SCADA alert generated immediately.
Lift conveyor divert gate activates — material routed to Quarantine Bay QA-01. Lift conveyor pauses.
Tipping operations for Trough 1 suspended until QA-01 inspection complete.
QA-01 water deluge activates automatically on temperature confirmation above 120°C.
Operations supervisor notified immediately — quarantine log entry created.
⚠ QA-01 Entry Requirements — Strict Compliance
No personnel may enter QA-01 until: CO concentration <25 ppm (confirmed by calibrated meter) AND temperature <40°C.
LOTO required on water deluge system before personnel entry. Two-person minimum at all times in QA-01.
Full PPE including SCBA if CO or temperature cannot be confirmed prior to entry.
12. Startup Sequence — Modules 0A/0B/0C
Startup Rule — APS First, Always
Step 1 is mandatory and non-negotiable. No other equipment may be started until APS is confirmed running and negative pressure is confirmed in the Dumping Floor zone.APS confirmed running and negative pressure confirmed (–0.05 to –0.10 in. WC). MANDATORY FIRST STEP — do not proceed if failed.
EASB door controls enabled — Lane A and Lane B.
Leachate sump pump set to AUTO.
Walking floors set to STANDBY — Trough 1 and Trough 2.
Lift conveyors set to STANDBY.
Trough 2 feed conveyors set to STANDBY.
Bridge hydraulic power units ON — pressure confirmed on SCADA.
Bridge controls enabled — all bridges confirmed DOWN and latched on position sensors.
Thermal detection camera confirmed active.
Dumping Floor LED bay assignment system active — test display cycle.
Module 0A/0B/0C READY: Notify TISAB to begin truck intake. Notify OPS-003 (Shredder Train) and OPS-004 (Trough 2 Processing).
13. Shutdown Sequence
Shutdown Rule — APS Last, Always
The APS must remain running until all material has been cleared from the Dumping Floor building and all enclosures are sealed. Do not shut down APS while any trough, bridge, or conveyor is active.Notify dispatch: no new truck assignments. Allow in-transit trucks to complete their cycle.
Stop Trough 1 and Trough 2 walking floors after last truck completes tipping.
Allow lift conveyors to run until material clear — confirm empty by level sensor and visual.
Stop lift conveyors. Stop Trough 2 feed conveyors.
Lower all bridges — confirm DOWN and latched on all position sensors.
Bridge HPUs OFF after bridges confirmed down.
Leachate sump pump to MANUAL — confirm sump pumped down before shutdown.
Door controls disabled — all doors confirmed closed and sealed.
APS shutdown only after building fully sealed and all equipment stopped. Notify APS operator — coordinate APS shutdown timing.
14. Emergency Procedures
| Emergency | Immediate Action | SCADA Action | Escalation |
|---|---|---|---|
| Fire in Dumping Floor building | Activate building E-stop pull cord — all doors hold. Evacuate building immediately. Muster point per site plan. | All doors freeze in current position. APS continues. NFPA suppression activates. | Emergency services. Facility emergency coordinator. |
| Li-battery thermal event at trough | Activate nearest E-stop. Do not approach. Move to muster point. | Divert gate to QA-01. Water deluge auto-activates above 120°C. | Emergency coordinator. Fire brigade. QA-01 protocol Section 11. |
| APS pressure loss during tipping | Stop tipping — lower bridge immediately per Section 10.3. | Auto-lower command issued. Alarm logged. | APS operator. Operations supervisor. |
| Bridge stuck in raised position | Stop all tipping operations. Do not attempt manual lowering without LOTO. | Fault state B5. All further bridge raises locked. | Maintenance LOTO procedure. Engineering on call. |
| Person under raised bridge | Activate nearest E-stop immediately. Bridge holds in current position. | E-stop logged. All bridge motion locked. | Emergency services immediately. Do not lower bridge until personnel confirmed clear. |
15. Performance KPIs
| KPI | Target | Alarm Threshold | Measurement Basis |
|---|---|---|---|
| Truck processing rate | >30 trucks/hr per lane | <25 trucks/hr sustained | SCADA load records per shift |
| Airlock cycle time | <3 minutes per truck | >5 minutes sustained | SCADA door state timestamps |
| Payload reconciliation accuracy | ≥98% of loads within ±5% | <95% in any shift | SCADA reconciliation log per shift |
| Bridge raise/lower cycle | <60 seconds each direction | >90 seconds | SCADA bridge state timestamps |
| Dumping Floor negative pressure | –0.05 to –0.10 in. WC at all times | Above –0.03 in. WC for >30 sec | Continuous SCADA pressure monitoring |
| Leachate zero discharge compliance | 100% — zero discharge events | Any discharge event | Leachate tank level and pump logs |
| Li-battery quarantine response time | <60 seconds from detection to divert | >90 seconds | SCADA thermal camera alarm to divert gate confirmation |
END OF DOCUMENT — CBT-PRE-OPS-002 | Rev 0 | April 2026 | CONTROLLED — CARBOTURA INC.
Pregenesis Protocol Operations | Modules 0A / 0B / 0C | Governed by CBT-PRE-OPS-001 Master Protocol
Pregenesis Protocol Operations | Modules 0A / 0B / 0C | Governed by CBT-PRE-OPS-001 Master Protocol