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

Doc No.CBT-PRE-OPS-004

RevisionRev 0

StatusIssued for Review

ExtendsCBT-PRE-OPS-001 through -003

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 manufacturing susceptor product. 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 (decanter centrifuge or belt filter press) → Paddle dryer (indirect steam, 130–160°C) → 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 for susceptor product homogeneity; quality adjustment

1. Pre-Operation Checklist

□ 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 → Paddle Dryer → Impact Mill → Sludge Silo
>60%	Sludge	Pre-dewatering MANDATORY	Centrifuge (mandatory) → Paddle Dryer → 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. Paddle Dryer Operations

Parameter	Value	Notes
Operating temperature	130–160°C (steam-heated)	Indirect steam — no direct flame contact with process material
Steam supply	3–10 bar	Confirm at steam header before startup
Drying target	Moisture <15% by weight	Required for VRM pulverizer performance
Vapor condenser	Cooling water confirmed flowing before dryer startup	Condensate is a high-value water product — route to water treatment, NOT to leachate
APS capture	60–120°C vapor capture from dryer discharge zone	Route to condensate recovery — not atmospheric discharge

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

⚡ 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

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	Paddle dryer 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