Pregenesis Protocol — Operational Procedure

Primary Shredding, Hammermill, Ash Pulverizer, Rotational Mixer & Regenesis Feed Train

Modules 1–4 — Shredder Train Operations | Complete operational procedures from Trough 1 discharge to Regenesis Feed Metering Bin

Doc No.CBT-PRE-OPS-003

RevisionRev 0

StatusIssued for Review

OwnerCarbotura Inc. — Operations

ParentCBT-PRE-OPS-001

Manufacturing Classification Notice

This protocol governs manufacturing feedstock preparation operations. No waste treatment, storage, or disposal activities are defined or implied. Manufacturing Feedstock is processed as an input material for Carbotura Advanced Circular Manufacturing.

1. Purpose & Scope

This document governs the complete operation of the Pregenesis Shredder Train from Trough 1 lift conveyor discharge through delivery of metered, blended Manufacturing Feedstock to the Regenesis Feed Metering Bin discharge. It defines operational requirements, startup and shutdown sequences, normal operating procedures, and emergency response for all Shredder Train modules.

Boundary	Description
Upstream	Trough 1 lift conveyor discharge — governed by CBT-PRE-OPS-002
Downstream	Regenesis Feed Metering Bin discharge to Regenesis reactor inlet — governed by Regenesis Protocol

2. Pre-Operation Checklist

APS First — Always

APS must be confirmed running and negative pressure established in all Shredder Train enclosures before any equipment is started. This is non-negotiable.

□ MANDATORY: APS running and negative pressure confirmed in all shredder train enclosures

□ All E-stop pull cords reset — visual confirmation each cord

□ Fire suppression systems armed — shredder, hammermill, pulverizer CO₂ systems

□ Ash silos level above LOW alarm — both Stream A and Stream B confirmed independently

□ SCADA AFR setpoint confirmed — default AFR = 0.25. Confirm with Regenesis operator before adjusting.

□ All belt tensions visual check — all conveyors

□ Hydraulic oil levels — shredder and tire pre-shredder HPUs

□ MANDATORY: Ash pulverizer zone LEL sensors showing 0% reading on SCADA

□ Ferrous collection bins FCB-001 through FCB-004 all below HIGH alarm

□ CO monitor inside shredder enclosure confirmed active

□ Loss-in-weight feeders calibration check — within ±0.5% of setpoint

□ Operator shift briefing complete — all personnel briefed on shift targets and hazards

3. Startup Sequence — Full Shredder Train

Start Downstream First — Work Upstream

Always start from the Regenesis Feed Metering Bin back toward Trough 1. This ensures downstream capacity is available before upstream equipment begins feeding. Never start a feeder before its receiving equipment is running.

APS confirmed running — negative pressure in all enclosures. MANDATORY FIRST STEP. Do not proceed if APS not confirmed.

Start Regenesis Feed Metering Bin discharge feeder to STANDBY mode — zero flow, demand signal from Regenesis controls actual output.

Start Mixer discharge conveyor (SHRD-CV-007: mixer to Regenesis Feed Bin). Confirm running on SCADA before proceeding.

Start Rotational Mixer — primary unit. Confirm drum rotation, drive amps nominal.

Ash loss-in-weight feeders to STANDBY — zero flow, ready for ramp command.

Start Ash Pulverizer — primary unit. Classifier up to full speed, confirm amps nominal before proceeding.

Start ash-to-mixer conveyor (SHRD-CV-004).

Start Hammermill discharge conveyor (SHRD-CV-003: hammermill → MFS-003/004 → mixer).

Start Hammermill — primary unit. Rotor MUST reach full speed before any feed is introduced. Confirm RPM on SCADA before proceeding to next step.

Start MFS-003/004 (post-hammermill magnetic separator belt drive).

Start Primary Shredder discharge conveyor (SHRD-CV-002).

Start Primary Shredder — primary unit. Confirm drive amps nominal, test auto-reverse function.

Start MFS-001/002 (post-shredder magnetic separator belt drive).

If tire stream active: start Tire Pre-Shredder.

Start Trough 1 walking floor at low speed (20% of design rate).

Ramp ash loss-in-weight feeders to AFR = 0.25 over 5 minutes. Monitor shredder amps, hammermill amps, AFR actual vs. setpoint on SCADA. Confirm all nominal within 5 minutes. System RUNNING — notify Trough 1 operations and Regenesis operator.

4. Normal Operating Procedures

4.1 AFR Blend Ratio Control

SCADA formula: Ash Setpoint (TPH) = Feedstock Flow (TPH) × AFR Setpoint. Default AFR = 0.25. Operating range: 0.0 to 1.0. Operator adjusts AFR setpoint from SCADA HMI only — no manual adjustment of loss-in-weight feeders except during calibration.

Condition	Threshold	Required Action
AFR actual deviation	Deviates >0.02 from setpoint for >2 minutes	Investigate ash feed system — check loss-in-weight feeders, silo levels, conveyor status
AFR drop to zero	AFR = 0.0 for >5 minutes	Alert Regenesis operator immediately — susceptor supply may be interrupted
Ash silo LOW-LOW (both)	Both silos at LOW-LOW simultaneously	Initiate Regenesis feed pause — do not continue Shredder Train operation without susceptor

4.2 Feed Rate Management

Trough 1 walking floor speed is SCADA-controlled based on the Regenesis demand signal. If shredder motor amps approach 90% of rated current, reduce walking floor speed immediately — do not overload the shredder drive. Hammermill feed rate is controlled by the shredder discharge conveyor speed (variable drive).

4.3 Hammermill Screen Monitoring

Condition	Indicator	Action
Screen wear — progressive	Throughput drop >15% at constant feed rate; recirculation rate rising	Schedule screen swap on standby unit during next planned window
Oversize detected	Grizzly alarm; recirculation rate >5% sustained >10 min	Conduct immediate screen inspection on standby unit; prepare for hot swap
Screen failure — catastrophic	Recirculation rate >40%; oversize material bypassing to mixer	Emergency stop hammermill; switch to standby unit; LOTO primary for screen replacement

5. Two-Stage Ferrous Removal Operations

Stage	Equipment	Location	Ferrous Collection Bin	Target Removal
Stage 1	SHRD-MFS-001/002	Post-primary shredder discharge	FCB-001 / FCB-002	Bulk ferrous — appliance frames, cans, wire, mattress springs
Stage 2	SHRD-MFS-003/004	Post-hammermill discharge	FCB-003 / FCB-004	Fine wire, fasteners, composite fragments liberated by hammermilling

FCB FULL alarm: operator must empty the collection bin immediately. Do not allow overflow onto conveyor structure — this is a production stop condition. Log FCB emptying events per shift with volume estimate for mass balance reporting.

6. Ash Pulverizer Operations

⚡ ATEX Zone 21 — Class II Division 1

All electrical equipment within the ash pulverizer zone must be rated for Class II Division 1 / Zone 21 service. No smoking, no open flame, no non-intrinsically-safe electronic devices within zone boundary. Hot work permit required for any work within 20 ft of the pulverizer enclosure.

LEL Reading	Alarm Level	Required Action
10% LEL	WARNING	Generate alarm. Increase APS extraction rate. Reduce pulverizer feed rate.
25% LEL	CRITICAL	Auto-shutdown pulverizer. N₂ purge activates automatically. Do not restart until LEL <5% for 10 continuous minutes.
40% LEL	EMERGENCY	Full Pregenesis E-stop. Emergency response team notification. Do not re-enter zone without emergency team clearance.

Silo Level	Threshold	Action
HIGH	>80% capacity	Reduce pulverizer throughput rate
LOW	<20% capacity	Increase pulverizer throughput rate
LOW-LOW	<10% capacity	Alert Regenesis operator — do not reduce Regenesis feed rate without Regenesis confirmation
Anti-bridging	<30% level	Anti-bridging vibrators auto-activate to prevent arch formation at silo outlet

7. Shutdown Sequence

Shutdown Rule — Feed Upstream First, Stop Downstream Last

Stop feeding from the upstream end first, then let each stage run clear before stopping it. APS must remain running until all enclosures are confirmed empty and sealed.

Stop Trough 1 walking floor — stop all new feed to shredder train.

Allow Primary Shredder to run clear — confirm discharge conveyor flow drops to zero on belt scale. Stop Primary Shredder.

Stop Tire Pre-Shredder if active.

Allow Hammermill to run clear — confirm discharge flow to zero. Stop Hammermill.

Ramp ash loss-in-weight feeders to zero over 2 minutes — stop feeders. Stop Ash Pulverizer after feeder zero confirmed.

Allow Rotational Mixer to run clear — confirm no feed entering. Stop Rotational Mixer.

Stop all conveyors in sequence from upstream to downstream, confirming each is clear before stopping.

Stop Regenesis Feed Metering Bin discharge feeder — notify Regenesis operator of feed stop.

APS shutdown only after all enclosures confirmed empty and sealed. Coordinate with APS operator for shutdown timing.

8. Emergency Procedures

Emergency	Immediate Action	Escalation
Shredder jam / overload (>90% amps sustained)	Reduce walking floor speed immediately. If amps don't drop within 30 sec, stop walking floor. If rotor stalls: initiate controlled shutdown — LOTO before any manual intervention.	Maintenance LOTO team. Engineering on call if jam cannot be cleared within 2 hours.
Li-battery thermal event in shredder enclosure	Activate nearest E-stop pull cord. Evacuate area. CO monitor alarm confirms thermal event. Water deluge activates on temperature confirmation.	Emergency services. Facility emergency coordinator. QA-01 protocol per OPS-002 Section 11.
Hammermill screen breakthrough (massive oversize)	Stop hammermill immediately. Switch to standby unit. Do not attempt to continue on failed screen.	Maintenance LOTO for screen replacement. Engineering review if enclosure damage suspected.
LEL 25% or higher in APZ zone	APZ auto-shuts down. N₂ purge activates. Evacuate APZ zone. Do not re-enter until LEL <5% for 10 continuous minutes confirmed by SCADA.	Operations supervisor. Safety Lead. Emergency response team if LEL >40%.
AFR deviation — total susceptor loss	Alert Regenesis operator immediately. Check silo levels and all conveyor status. If both silos at LOW-LOW: pause Regenesis feed per Regenesis Protocol.	Operations supervisor. Ash supply chain team for emergency delivery if needed.

9. Performance KPIs

KPI	Target	Alarm Threshold
Shredder throughput	40–60 TPH per active unit	<35 TPH at full walking floor speed — investigate
Hammermill P80 output	≤25 mm (1 in. screen)	Recirculation rate >5% sustained >10 min
AFR accuracy	0.25 ±0.02 sustained	Deviation >0.02 for >2 min; RevCon warranty trigger at >0.05
Blend uniformity (CV)	<5% per shift grab sample	>8% requires immediate investigation
Ash pulverizer output	<500 µm D90	>600 µm D90 — reduce feed rate; inspect rollers
Two-stage ferrous removal	≥99% at ≥10 mm; ≥95% at ≥5 mm	Ferrous recovery rate <80% vs. baseline — inspect magnet pull-force
Negative pressure — all enclosures	–0.075 in. WC (mid-range)	<–0.05 in. WC or >–0.10 in. WC for >30 sec