Pregenesis Protocol — Operational Procedure
Trough 2 Ash & Sludge Processing — Drying, Dewatering & Pulverizing
Module T2 — From Trough 2 walking floor discharge to pulverized ash delivery to Shredder Train silos
Manufacturing Classification Notice
All materials received at Trough 2 are classified as Manufacturing Feedstock or process material for Carbotura Advanced Circular Manufacturing. WTE ash is processed as a Enhancement Admix material (Recyclotron Solid Phase OmniCrude™ or WTE Ash). No waste treatment, storage, or disposal activities are defined or implied.Module T2 Overview — Selective Merge Architecture
Sludge Path: Trough 2 walking floor → Divert gate → Pre-dewatering (centrifuge, if required per LCI test evaluation) → Indirect Thermal Dryer (T2-ITD) (indirect heat — Regenesis WHSG: steam, hot gases, or hot oil) → Impact/pin mill pulverizer → Pulverized sludge silo → Pneumatic transfer to Shredder Train (OPS-003)
Ash Path: Trough 2 walking floor → Divert gate → NIR moisture sensor → [Bypass dryer if <15%] or [Dryer trim/full cycle if ≥15%] → Lumpbreaker/cage mill → VRM pulverizer → Pulverized ash silo → Pneumatic transfer to Shredder Train (OPS-003)
| Mode | Name | Description | Use Case |
|---|---|---|---|
| Mode 1 | Separate (Default) | Both paths fully independent, each with dedicated pulverizer and silo | Default operating mode — maximum throughput and flexibility |
| Mode 2 | Merged | Sludge and ash paths merged before pulverizer — single train handles both | Maintenance on one pulverizer; lower throughput acceptable |
| Mode 3 | Sequential Blend | One path feeds into the other at a configurable ratio before pulverizer | Blending Enhancement Admix for feed homogeneity when Enhancement Mode active; feedstock-only homogenization in Baseline MCR Mode |
1. Pre-Operation Checklist
Pre-Operation Checklist — T2 Processing Train
□ MANDATORY: APS running and negative pressure confirmed in all T2 enclosures
□ Pneumatic transfer system to OPS-003 ash silos confirmed operational — test transfer line before feed
□ Shredder Train ash silos confirmed above LOW alarm — contact OPS-003 operator to confirm
□ Both T2 pulverizers on standby — classifier at full speed confirmed
□ Polymer day tank level >25% (if centrifuge/BFP active)
□ MANDATORY: N₂ supply to VRM pulverizer confirmed at pressure (6 bar, 99.9% purity) — ATEX Zone 21 inerting requirement
□ MANDATORY: LEL sensors in pulverizer zone showing 0% reading on all monitors
□ Leachate sump pump on AUTO — confirm pump responding to level
□ Dryer steam supply available at required pressure (3–10 bar) — confirm at steam header
□ Dryer vapor condenser cooling water flow confirmed
□ All divert gates position-confirmed — gate positions verified on SCADA HMI
□ NIR moisture sensor calibration confirmed within 30 days — check calibration log in SCADA
2. NIR Moisture Routing Logic
| NIR Reading | Material Class | Route Decision | Process Path |
|---|---|---|---|
| <15% | Ash | Bypass dryer | Lumpbreaker → VRM Pulverizer → Ash Silo |
| 15–30% | Ash | Dryer trim cycle | Lumpbreaker → VRM Pulverizer → Ash Silo |
| >30% | Ash | Full dryer cycle | Lumpbreaker → VRM Pulverizer → Ash Silo |
| <15% | Sludge | Flag anomalous — supervisor review required | Route to Ash Path (likely dried cake). Supervisor reviews before proceeding. |
| 15–60% | Sludge | Pre-dewatering → Dryer | Centrifuge (if required) → Indirect Thermal Dryer (T2-ITD) → Impact Mill → Sludge Silo |
| >60% | Sludge | Pre-dewatering MANDATORY | Centrifuge (mandatory for >60% moisture) → Indirect Thermal Dryer (T2-ITD) → Impact Mill → Sludge Silo |
| Mixed | Both | Split per programmed divert gate ratio | Both paths per SCADA selector |
3. Pre-Dewatering Operations — Sludge Path
3.1 Polymer Conditioning Startup
Confirm polymer day tank level >25%.
Start polymer dilution water supply — confirm flow on SCADA.
Start polymer make-up mixer — confirm solution at target concentration per sludge characterization sheet.
Set polymer dose rate on SCADA per current sludge characterization data.
Set polymer dosing pumps to AUTO mode — confirm SCADA confirmation.
3.2 Decanter Centrifuge — Primary Dewatering Unit
⚠ LOTO REQUIRED — Centrifuge Maintenance
LOTO required for any maintenance access to centrifuge bowl, scroll, or feed zone.
Confirm bowl at rest (0 RPM on SCADA) before opening any inspection cover. High-speed rotating component — stored rotational energy is significant even after power-off.
| Phase | Action | Indicator of Success |
|---|---|---|
| Startup | Spin up bowl to full RPM (5–10 min before feed). Confirm bowl RPM and differential speed on SCADA. Confirm centrate discharge line clear and open to leachate tank. | RPM stable; differential speed on SCADA; centrate line clear |
| Feed introduction | Open feed valve slowly while monitoring centrate clarity on SCADA camera. Centrate target: clear to slightly turbid. Cloudy centrate = insufficient polymer — increase dose, do not increase feed rate. | Clear-to-turbid centrate; cake discharge to dryer conveyor |
| Shutdown | Stop feed. Maintain bowl at full speed minimum 2 minutes after feed stops for self-discharge. Initiate flush sequence per SCADA shutdown routine. | Bowl self-discharge complete; flush confirmed |
Zero-Discharge Policy — Centrate
Centrate routing: 100% to leachate tank — ZERO external discharge under any condition. Any centrate reaching a floor drain or ground is a zero-discharge compliance event requiring immediate supervisor notification and incident report.4. Indirect Thermal Dryer (T2-ITD) Operations
4.1 Indirect Thermal Dryer (T2-ITD) — Operating Parameters
Indirect Thermal Dryer (T2-ITD) — OEM and Model
OEM: LCI Corporation (Nederman Group) · Charlotte, NC · lcicorp.comModel: Horizontal D-Dryer or Vertical CP Dryer — to be determined by LCI test center evaluation on representative Carbotura feedstock samples (sludge, WTE Ash, Coal Ash (wet bottom ash), Coal Mine Tailings, Critical Materials and Minerals (CMM) wet solids).
Heat source: Indirect contact — steam, hot gases, or hot oil delivered from Regenesis Waste Heat Steam Generator (WHSG) at the T2 module thermal boundary. Integrated WHSG hot oil exchanger or module-level heat exchanger — configuration determined at detailed engineering stage.
| Parameter | Value / Specification | Notes |
|---|---|---|
| OEM | LCI Corporation (Nederman Group) | Charlotte, NC · Nederman Group company |
| Model selection | Horizontal D-Dryer or Vertical CP Dryer | OPEN — OER Gate 2: LCI test center evaluation on representative Carbotura feedstock required before model selection |
| Heat source | Regenesis WHSG — steam, hot gases, or hot oil | Indirect contact heat transfer to dryer wall/jacket. No direct flame contact with process material. WHSG configuration (integrated or module-level exchanger) selected at detailed engineering. |
| Heat medium pressure | Per WHSG output and LCI test determination | LCI dryers rated for steam or hot oil service; pressure spec confirmed at LCI test center |
| Drying mechanism | Indirect contact — mechanically agitated thin film on heated wall | No large hot air volumes. Eliminates dilution air in APS vapor stream. Rotor blades maintain thin film: slurry → paste → powder. |
| Discharge form | Dry flowable powder or cake, <1% moisture achievable | Airlock discharge valve. Discharges directly to VRM pulverizer or admix silos depending on particle size achieved. |
| Drying target | Moisture <15% w.b. for VRM feed; <1% achievable | VRM performance requires <15%. Further drying possible if admix silo storage requires <1%. |
| Vapor output | Counter-current concentrated vapor — to condenser | No dilution air — concentrated vapor exits counter-currently, goes to condenser. Condensate is a high-value water product — route to water treatment. NOT to leachate stream. |
| APS connection | Vapor capture at dryer discharge zone | Concentrated vapor — high condensate recovery value. Route to APS condensate recovery, not atmospheric discharge. |
| Feed streams handled | Sludge, WTE Ash, coal tailings, wet CMM solids | All wet industrial carbon streams entering via Trough 2. Centrifuge pre-dewatering requirement for high-moisture feeds (>60%): OPEN — OER Gate 2, LCI test center evaluation. |
| Operating pressure | Vacuum or atmospheric | Per LCI test center determination for Carbotura feedstock blend |
Condensate is a Product Stream — Not a Waste Stream
Dryer condensate is high-value ultrapure water produced during the drying process. It routes directly to the water treatment module for product recovery. It must never be discharged to leachate or to drain. Incorrect routing is a product loss and a compliance event.5. VRM Pulverizer Operations — Ash Path
5.1 ATEX Zone 21 Requirements
⚡ ATEX Zone 21 — VRM Pulverizer Zone
N₂ inerting must be confirmed at pressure before VRM startup. LEL sensors must read 0% before startup. Hot work permit required for any work within 20 ft of pulverizer enclosure.
| Target | Value | If Out of Spec |
|---|---|---|
| Product fineness | <500 µm D90 | Reduce feed rate; inspect roller wear — sample and sieve per shift |
| N₂ supply pressure | ≥6 bar at VRM connection | Low-pressure SIL 1 interlock prevents VRM start; investigate N₂ supply before restart |
| LEL at startup | 0% on all zone sensors | Do not start until LEL confirmed 0% — investigate and purge if any reading above 0% |
| Roller wear indicator | Specific energy within 20% of OEM baseline | Schedule roller inspection on standby unit; arrange OEM grindability retest if wear rate anomalous |
6. Leachate & Condensate Management
6.1 Leachate Stream — Water Treatment Routing
| Stream | Source | Routing | Zero-Discharge Rule |
|---|---|---|---|
| Centrate | Decanter centrifuge | 100% to leachate collection tank | Zero discharge to drain or ground — compliance event if violated |
| Filtrate | Belt filter press | 100% to leachate collection tank | Zero discharge to drain or ground — compliance event if violated |
| Condensate | Indirect Thermal Dryer (T2-ITD) vapor condenser | 100% to water treatment module — HIGH-VALUE product stream | Must NOT go to leachate — product loss and compliance event if misrouted |
| Floor drains (T2 zone) | Wash water, incidental spills | Gravity to leachate sump | Zero discharge to storm drain or ground — all wash water to leachate |
END OF DOCUMENT — CBT-PRE-OPS-004 | Rev 0 | April 2026
| CONTROLLED — CARBOTURA INC.
Trough 2 Processing Operations | Module T2 | Governed by CBT-PRE-OPS-001 Master Protocol
7. Shutdown Sequence — T2 Processing
7.1 Planned Shutdown
Stop new Trough 2 rear discharge — allow walking floor to clear remaining material to downstream processing.
NIR sensor: leave online until dewatering centrifuge feed stops. Log final moisture readings for shift report.
Centrifuge: complete active dewatering batch. Do not stop centrifuge with partially processed sludge in bowl — risk of imbalance on restart.
Indirect Thermal Dryer (T2-ITD): run to empty — confirm powder discharge at airlock valve has stopped. Set dryer to standby heat-hold mode heat mode if downtime <8 hours; cool-down mode if >8 hours.
VRM pulverizer: run until feed hopper empty. Confirm classifier clear. Lock main disconnect. Apply LOTO if >4 hours downtime.
Leachate system: confirm transfer pump stopped, transfer valve closed. Verify no accumulation in collection sump.
Complete T2 shift log: tonnage by stream (sludge dewatered, ash pulverized, leachate removed, condensate recovered), dryer thermal performance, and any faults.
7.2 Extended Shutdown — Maintenance
For shutdowns exceeding 24 hours: fully drain leachate collection sump. Flush centrifuge bowl with fresh water per OEM maintenance procedure. Cool Indirect Thermal Dryer (T2-ITD) to ambient temperature before opening for inspection per LCI maintenance procedure. Apply LOTO to all T2 drives. Notify maintenance for scheduled PMI items (CBT-PMI-T2-001 through -004).
8. Emergency Procedures — T2 Processing
8.1 Emergency Response Table
| Emergency | Immediate Action | Do Not |
|---|---|---|
| Indirect Thermal Dryer (T2-ITD) wall temperature exceedance (>180°C shell) | Stop feed immediately. Open bypass damper. Reduce steam pressure. If >200°C: E-stop dryer, isolate steam supply, notify engineering. | Do not open dryer access doors while above 100°C |
| VRM pulverizer — ATEX alarm / spark detection | E-stop pulverizer. Isolate N₂ inert supply — confirm N₂ flow maintained. Do not re-enter ATEX zone without gas-free certificate. | Do not open any explosion-relief panel — stand clear |
| Centrifuge vibration alarm / imbalance | E-stop centrifuge — controlled stop via VFD coast. Do not apply emergency brake. Wait for full stop before inspection. | Do not open bowl access while rotating |
| Leachate overflow / spill | Stop transfer pump. Contain spill with available absorbent. Notify environmental compliance. Log volume estimate in SCADA. | Do not discharge uncontained leachate to storm drain |
| Loss of APS negative pressure — T2 zone | Stop all T2 processing. Close zone isolation dampers. Investigate APS fan and duct. Resume only after pressure restored and confirmed >5 min. | Do not open trough or dryer access during pressure loss |
9. Performance KPIs — T2 Processing
9.1 Key Performance Indicators
| KPI | Target | Alarm Threshold | SCADA Tag |
|---|---|---|---|
| Sludge dewatering rate | ≥50% moisture reduction (wet to dry basis) | <40% reduction for 3 consecutive batches | T2-PRF-DEWAT-001 |
| Dryer outlet moisture | <15% (w.b.) for VRM feed | >20% moisture — stop feed to VRM | T2-PRF-DRY-001 |
| VRM product fineness (D90) | P80 <500 µm | >600 µm D90 on grab sample | T2-PRF-VRM-001 |
| Leachate recovery | 100% capture — zero discharge | Any sump overflow alarm | T2-PRF-LCH-001 |
| Condensate recovery | >90% of dryer evaporation captured | <80% capture rate | T2-PRF-CON-001 |
| T2 throughput availability | ≥92% of scheduled operating hours | <85% in any 7-day rolling period | T2-PRF-AVL-001 |
Trough 2 Processing Operations | Module T2 | Governed by CBT-PRE-OPS-001 Master Protocol