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
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.Pre-Operation Checklist — Complete before initiating Shredder Train startup
□ 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 — Enhancement Admix streams (Stream A: WTE Ash, Stream B: Recyclotron Solid Phase OmniCrude™) confirmed independently
□ SCADA EAF setpoint confirmed — default EAF = 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
3.1 Startup Order — Downstream First Rule
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 EAF = 0.25 over 5 minutes. Monitor shredder amps, hammermill amps, EAF 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 EAF Blend Ratio Control
SCADA formula: Ash Setpoint (TPH) = Feedstock Flow (TPH) × EAF Setpoint. Default EAF = 0.25. Operating range: 0.0 to 1.0. Operator adjusts EAF setpoint from SCADA HMI only — no manual adjustment of loss-in-weight feeders except during calibration.
| Condition | Threshold | Required Action |
|---|---|---|
| EAF actual deviation | Deviates >0.02 from setpoint for >2 minutes | Investigate ash feed system — check loss-in-weight feeders, silo levels, conveyor status |
| EAF drop to zero | EAF = 0.0 for >5 minutes | Switch to Baseline MCR Mode — set EAF setpoint to 0.00, continue operations. Notify Regenesis operator of mode change. Investigate admix supply interruption. |
| Ash silo LOW-LOW (both) | Both silos at LOW-LOW simultaneously | Initiate Regenesis feed pause — continue Shredder Train at Baseline MCR Mode (EAF = 0.00) — Enhancement Admix is optional, not a process requirement |
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
5.1 Stage 1 — Post-Primary Shredder (MFS-001/002)
| 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
6.1 ATEX Zone 21 Requirements and Pre-Start Checks
⚡ 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%. |
| EAF deviation — Enhancement Admix loss (switch to Baseline MCR Mode) | Alert Regenesis operator immediately. Check silo levels and all conveyor status. If both silos at LOW-LOW: set EAF = 0.00, continue Regenesis at Baseline MCR Mode. Enhancement Admix is not a process requirement — Regenesis does not pause on admix loss. | 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 |
| EAF 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 |
END OF DOCUMENT — CBT-PRE-OPS-003 | Rev 0 | April 2026 | CONTROLLED — CARBOTURA INC.
Pregenesis Shredder Train Operations | Modules 1–4 | Governed by CBT-PRE-OPS-001 Master Protocol
Pregenesis Shredder Train Operations | Modules 1–4 | Governed by CBT-PRE-OPS-001 Master Protocol