Pregenesis Protocol — Master Architecture
Pregenesis Protocol
Full Module Architecture & PIMB Integration
Master Integration Document — All Pregenesis Modules | PIMB Architecture | Facility Context | Cross-Module Interfaces
Document Control
| Document Number | CBT-PRE-TDS-001 |
| Revision | Rev 2 — April 2026 |
| OER Classification | Class 2 (±15%) OEM Engineering Release — equivalent to "FEED / DOE FEL-3" [external regulatory reference — DOE LPO / AACE 18R-97 only] |
| Status | WORKING DOCUMENT — Pre-Release Engineering Development |
| Owner | Carbotura Inc. — Engineering |
| Quality Standard | ISO 9001:2015 |
| Authorized Strategic Integrator (ASI) | Role open to qualified ASI candidates per CBT-ASI-QUAL-001. ASI (Authorized Strategic Integrator) — designation pending final partnership execution. |
| RevCon Performance Baseline | RevCon 3 — $150M–$325M/yr revenue floor, 400 TPD canonical baseline |
| Capacity Basis | 1,000 TPD nameplate / 400 TPD canonical engineering baseline |
| Chairman | Allen Witters |
Revision History
| Rev | Date | Author | Description |
|---|---|---|---|
| 0 | March 2026 | Carbotura Engineering | Initial Issue — Class 4 Preliminary (±30%). |
| 1 | April 2026 | Lead Systems Architect | Class 2 OER Upgrade — ASI terminology applied, Terminology Firewall enforced, RevCon 3 baseline. |
| 2 | April 2026 | Lead Systems Architect | Session 9 updates: RC0 hand-off architecture; LMS canonical naming; 30kV MVDC backbone; Liquifact vapor → WHSG dirty steam circuit; net feedstock 345–350 TPD. |
Table of Contents
- Executive Summary
- Facility Context & Building Architecture
- Process Description
- Operating Conditions
- Module Interface Summary
- Equipment Summary
- Utility Summary
- Controls & SCADA
- Vendor Matrix
- CAPEX Summary
- TIC WBS Reconciliation
- Lead Time Schedule
- TRL / ERL / IRL Assessment
- Confidence Factor
- Availability Model
- Risk Register
- Spares Register
- Warranty Register
1. Executive Summary
Document Boundary Statement
This Technical Design Specification defines module-level technical requirements, interfaces, testing, and warranty boundaries only. Commercial risk allocation, financing structures, and lender requirements are addressed in separate contractual documents.Manufacturing Classification
This document describes module-level requirements for an Advanced Circular Manufacturing subsystem and does not define or imply waste treatment, storage, or disposal activities.Near-Zero Design Intent
The Pregenesis Protocol is engineered as a closed-loop manufacturing subsystem designed for near-zero emissions, near-zero discharge, and near-zero residual. Achieved through enclosed material handling, continuous negative-pressure APS operation, and absence of routine discharge pathways.Revenue Performance Baseline
All throughput guarantees and performance metrics are baselined to RevCon 3: $150M–$325M/yr revenue floor at 400 TPD baseline factory configuration.Authorized Strategic Integrator
The ASI packages, factory-assembles, performance-tests, and delivers all modules as Serial-Numbered OEM Products to Carbotura specification authority. The ASI issues the Unitized Warranty Passport upon FAT completion for each serial-numbered module.TDS-001 is the master architecture document for the Pregenesis Protocol. It defines the integration of all Pregenesis modules within the Pregenesis Integrated Manufacturing Building (PIMB) and the protocol boundary at the Recyclotron Feed Header (RFH). Detailed engineering for individual modules is in child TDS documents: CBT-PRE-TDS-002 (Modules 0A/0B/0C/0D Feedstock Ingest), CBT-PRE-TDS-003 (Shredder Train), CBT-PRE-TDS-004 (T2 Processing), CBT-PRE-TDS-005 (Liquifact Collection and Evaporation).
2. Facility Context & Building Architecture
2.1 Two-Building Architecture
| Parameter | Value |
|---|---|
| Pregenesis Integrated Manufacturing Building (PIMB) | Single dedicated structure — Modules 0A, 0B, 0C, 0D, T2 Processing, Shredder Train (Modules 1–7), PRE-LFB-001, PRE-EVP-001 (×2), APS Equipment Room, Control Room, Maintenance Bay |
| PIMB footprint | ~69,600 sq ft — D-66 Open — discrepancy with ECN-002 Rev 1 (~72,600 sq ft) — see R-06 |
| Regenesis Manufacturing Building (RMB) | Separate structure — all Regenesis Protocol modules. Defined in CBT-REG-TDS-001 |
| PIMB–RMB interface | Recyclotron Feed Header (RFH) penetration (ASI-RFH-FLG) at shared building wall. NXS-Z2 cross-zone routing for WHSG steam to PRE-EVP-001 |
| TISAB / EASB section type | Rigid steel frame with insulated metal panel |
| Main Dumping Floor | Clear-span structural fabric (sprung) building on reinforced concrete slab |
| Heavy mobile equipment in PIMB | ZERO — all tipping accomplished by truck geometry and hydraulic drawbridge system |
| Nameplate capacity | 1,000 TPD as-received — single PIMB serves all Regenesis modules at any scale |
2.2 Pregenesis Module Register — Complete
| Module | Tag | Document | Function |
|---|---|---|---|
| 0A | TISB-BLD-001/002 | TDS-002 | Truck Intake & Scale Airlock Building (TISAB) |
| 0B | DUMP-BLD-001 | TDS-002 | Dumping Floor and Dual-Trough System |
| 0C | TISB-BLD-003/004 | TDS-002 | Exit Airlock Scale Building (EASB) |
| 0D | LBS-MNF-001 et al. | TDS-002 | Liquid Biosludge Station |
| T2 | T2-ITD-001/002 | TDS-004 | Trough 2 Processing — Indirect Thermal Dryer |
| 1 | SHRD-TPS-001/002 | TDS-003 | Tire Pre-Shredder |
| 2 | SHRD-SHR-001/002 | TDS-003 | Primary Shredder |
| 3 | SHRD-TMD-001 | TDS-003 | Tramp Metal Detector |
| 4 | SHRD-MFS-001 et al. | TDS-003 | Multi-Fraction Screen Train |
| 5 | SHRD-HMR-001/002 | TDS-003 | Hammermill |
| 6 | SHRD-MXR-001/002 | TDS-003 | Rotational Mixer |
| 7 | SHRD-RFB-001/002 | TDS-003 | Regenesis Feed Metering Bin |
| PRE-LFB-001 | PRE-LFB-001 | TDS-005 | Liquifact Collection & Buffer — facility-wide drip pans, wastewater, dryer condensates |
| PRE-EVP-001 | PRE-EVP-001 (×2) | TDS-005 | Liquifact Thin-Film Evaporator — 2:facility redundant pair. Steam from WHSG NXS-Z2. |
Optional Enhancement Equipment: SHRD-APZ (Enhancement Admix Pulverizer), SHRD-EAS (Enhancement Admix Storage), SHRD-LWF (Loss-in-Weight Feeder). Not required for Baseline MCR Mode.
3. Process Description
3.1 Protocol Narrative
Manufacturing Feedstock arrives at the PIMB TISAB by truck fleet: 53-ft end-dump semis, walking floor semis, compression trucks, dump trucks, and tanker trucks. SCADA reads the vehicle manifest and routes each truck to the appropriate bay. Solid feedstock is deposited into Trough 1 (→ Shredder Train) or Trough 2 (→ T2 Processing). Liquid biosludge routes to Module 0D.
The Shredder Train reduces all solid feedstock to a uniform particle size, screens for tramp metal (SHRD-TMD), hammer-mills to final size, and optionally blends with Enhancement Admix (EAF = 0.05–0.35, target 0.25 in Enhanced MCR Mode). Blended Manufacturing Feedstock is metered into the Regenesis Feed Metering Bin (SHRD-RFB) for delivery to the Recyclotron Feed Header (RFH) at the PIMB–RMB interface.
Trough 2 processing centrifuges, dries (T2-ITD — Indirect Thermal Dryer, 200–400°C, steam from REG-WHSG-001 via NXS-Z2), pulverizes, and classifies the Enhancement Admix fraction. Liquifact collected from all Pregenesis modules routes to PRE-LFB-001 buffer, then to PRE-EVP-001 thin-film evaporators. Vapor stream routes to WHSG dirty steam circuit for MCR injection. Liquifact Minerals Stream (LMS — evaporator concentrate) routes to SHRD-MXR-001 as blending input.
APS (Atmospheric Protection System) maintains continuous negative pressure throughout the PIMB. All airborne particulates and vapors are captured in the APS Capture Stream — no routine atmospheric discharge.
3.2 RC0 Hand-Off — Pregenesis to Regenesis (Session 9)
| RC0 Stream | Mass (400 TPD basis) | Routing | Destination |
|---|---|---|---|
| Net Manufacturing Feedstock to Reactors | 345–350 TPD | ASI-RFH-FLG → REG-RCT-001 | 16 MCR Recyclotron reactors |
| Ferrous Metals | ~20.3 TPD Fe | RC0 direct bypass | REG-MRF (Regenesis MAX Metal Refining) |
| Aluminum | ~10.4 TPD Al | RC0 direct bypass | REG-MRF (Regenesis MAX) |
| Non-Ferrous (Cu/Zn/Pb) | ~3.3 TPD | RC0 direct bypass | REG-MRF (Regenesis MAX) |
| Liquifact Vapor Stream | 8–12 TPD | WHSG dirty steam circuit | 8 × MCR conical bottom injection points |
| Liquifact Minerals Stream (LMS) | 1.5–3 TPD | PRE-MXR-001 blending input | Returns to prime manufacturing loop |
3.3 Mass Flow — Key Parameters
| Parameter | Value | Basis |
|---|---|---|
| Total PIMB nameplate input | 1,000 TPD as-received | Locked |
| Canonical engineering baseline | 400 TPD | Locked — ARM-2026-001 |
| Trough 1 / Trough 2 split | ~90 / 10 | Portal Sankey — pending confirmation |
| EAF target (Enhanced MCR Mode) | 0.25 | ARM-2026-001 |
| EAF (Baseline MCR Mode) | 0.00 | No admix required |
| Liquifact collection rate | 10–20 gal/ton typical; 50 gal/ton peak surge | Session 9 |
| Net feedstock to reactors | 345–350 TPD | Session 9 — metals + Liquifact discounted |
4. Operating Conditions
| Parameter | Value |
|---|---|
| Throughput design basis | 1,000 TPD nameplate / 400 TPD canonical baseline |
| Operating hours | 24/7 continuous — 8,760 hr/yr design |
| Intake window | 12-hour daily delivery window |
| APS operating pressure | Continuous negative pressure — setpoint in APS TDS |
| T2-ITD thermal input | 200–400°C — WHSG High-Temperature Thermal Recovery (NXS-Z2) — D-THM-01 CLOSED PARAMETRIC |
| PRE-EVP-001 thermal input | WHSG High-Temperature Steam (NXS-Z2) |
| Enhancement Admix (EAF) | Optional — 0.00 baseline; 0.05–0.35 enhanced |
| Power source | Zero-E PowerBlock™ — 8 MW per 100 TPD Regenesis / 32 MW at 400 TPD |
| DC backbone voltage | 30kV MVDC (>100 TPD facilities) |
5. Module Interface Summary
5.1 PIMB Internal Interfaces
| Interface | From | To | Connector | Status |
|---|---|---|---|---|
| Trough 1 lift conveyor → Shredder | 0B Dumping Floor | Module 1 (SHRD-TPS) | Physical chute/hopper flange | Defined |
| Trough 2 walking floor → T2 | 0B Dumping Floor | T2 (T2-ITD) | Walking floor to T2 intake | Defined |
| T2 dry output → Enhancement Admix path | T2 (T2-ITD) | SHRD-EAS / SHRD-MXR | Pneumatic transfer | Defined |
| Shredder Train output → RFH | SHRD-RFB | PIMB–RMB wall | ASI-RFH-FLG | ECN-004 |
| Liquifact drain → LFB | All modules (drip pans) | PRE-LFB-001 | ASI-LFB-DRN | D-11 Open |
| LMS → Mixer blending input | PRE-EVP-001 (evap concentrate) | SHRD-MXR-001 | Gravity/pneumatic return | D-MXR-LMS-01 Closed |
| Evaporator vapor → WHSG dirty steam | PRE-EVP-001 | WHSG dirty steam circuit | Steam header connection | D-LIQ-STEAM-01 Closed |
5.2 PIMB–RMB Interface
| Interface | Connector | Spec | Status |
|---|---|---|---|
| RFH bulk material transfer | ASI-RFH-FLG | 12-in. ANSI 150# RF flange, CS rubber-lined | DEFINED — ECN-004 |
| NXS-Z2 WHSG steam to PRE-EVP-001 | ASI-NXS-Z2-QC | Cross-zone thermal routing | OPEN — D-24 |
| APS ductwork connection | ASI-APS-FLG | APS TDS pending | PENDING |
| NXS-Z1 Electrical | ASI-ZBK-MPC | 1,500V DC Zone Bus — Stäubli MPC | DEFINED — ARM-2026-002 |
6. Equipment Summary
Master-Level Summary
Module-level equipment specifications, OEM candidates, and performance parameters are in child TDS documents. This section provides master-level summary only.| Module Group | Key Equipment | OEM Reference | Child TDS |
|---|---|---|---|
| Modules 0A/0B/0C/0D | Hydraulic drawbridges, walking floors, NTEP weighbridges, PC pumps | Keith, Hallco, Mettler Toledo, Netzsch | TDS-002 |
| T2 Processing | T2-ITD (Indirect Thermal Dryer), Decanter centrifuge, Lumpbreakers, VRM | LCI Corp, Alfa Laval ALDEC, Pennsylvania Crusher, Gebr. Pfeiffer | TDS-004 |
| Shredder Train (Modules 1–7) | Tire pre-shredder, Primary shredder, Hammermill, Multi-fraction screen, VRM pulverizer, Rotational mixer, Feed metering bin | Vecoplan, Schutte, Gebr. Pfeiffer | TDS-003 |
| Liquifact System | PRE-LFB-001 buffer; PRE-EVP-001 thin-film evaporators (×2, redundant pair) | TDS-005 pending | TDS-005 |
7. Utility Summary
| Utility | Source | NEXUS Zone | PIMB Demand | Status |
|---|---|---|---|---|
| Electrical — MVDC Backbone | Zero-E PowerBlock™ | NXS-Z1 (30kV MVDC) | Facility-wide energy balancing | Defined |
| Electrical — Zone Bus | Zero-E PowerBlock™ | NXS-Z1 (1,500V DC) | 8 MW per 100 TPD / 32 MW at 400 TPD | ARM-2026-002 |
| Thermal — High Temp | REG-WHSG-001 (Process Gas Heat Recovery) | NXS-Z2 | T2-ITD: 200–400°C; PRE-EVP-001: steam | D-THM-01 Parametric |
| Thermal — Low Temp | Zero-E Thermal Recovery Stream (85–95°C) | NXS-Z2 | Preconditioning | Defined |
| N₂ — Dense Phase Injection | REG-GPU-001 PSA/membrane | NXS-Z3 | Recyclotron injection + HVAC purge | D-31 Locked |
| Steam — Dirty Circuit | PRE-EVP-001 vapor stream | WHSG Dirty Circuit | 8 × MCR conical bottom injection | D-LIQ-STEAM-01 |
| Steam — Clean Backup | REG-WHSG-001 secondary circuit | NXS-Z2 | MCR injection backup | Defined |
| APS — Negative Pressure | APS fan/recovery equipment | NXS-Z4 | Continuous facility-wide | APS TDS pending |
8. Controls & SCADA
PIMB SCADA manages vehicle manifest classification, bay routing, trough feed allocation, Shredder Train sequencing, T2 thermal control loop, Liquifact drain system monitoring, and APS negative pressure setpoints. All PLCs networked to central PIMB Control Room. SCADA interfaces to Regenesis SCADA via the RFH demand signal (protocol open — TDS-003 R-02).
Open Action ECN-A02
SCADA vehicle manifest classification and bay routing enforcement not formally specified. COMPRESSION truck flag must hard-interlock to prevent bridge-bay door opening (blade ejection geometry incompatibility = safety risk). Formalize ECN-A02 as SCADA design specification before SHRD-RFB controls are ordered.9. Vendor Matrix
American Manufacturing Preference Policy — ARM-2026-002 Cluster H
All Carbotura ACM Facility modules are assembled, tested, and warranted in the United States of America by the ASI. Equipment procurement adheres to Carbotura's American Manufacturing Preference Policy supporting DOE LPO domestic content requirements and Buy American Act alignment.Detailed vendor matrices with Country of Manufacture and Procurement Path columns are maintained in child TDS documents: TDS-002 §9, TDS-003 §9, TDS-004 §9. Compliance status is not confirmed without verified OEM documentation at RFQ stage. No vendor is declared INELIGIBLE without verified documentation.
10. CAPEX Summary
Class 2 Estimate Basis
All CAPEX estimates are Class 2 (±15%), 2026 USD basis. Master TIC rollup is OPEN pending TDS-005 production, NXS, ZEP, and APS TDS completion.Module-level CAPEX detail is in child TDS documents. See the CAPEX Summary portal page for the rolling master estimate. Full WBS breakdown in §11.
11. TIC WBS Reconciliation
Footprint Discrepancy — R-06
TDS-001 §2 states PIMB ~69,600 sq ft. CBT-PRE-ECN-002 Rev 1 states ~72,600 sq ft (~4.3% discrepancy). Must be resolved before site foundation design. D-66 open.| WBS | Scope | Low Estimate | High Estimate | AACE Class |
|---|---|---|---|---|
| 1.1 | Module 0A/0B/0C/0D — Intake, Trough, Airlock, Liquid Station | See TDS-002 §10 | Class 2 ±15% | |
| 1.2 | Module T2 — Trough 2 Processing (T2-ITD system, 2 units) | See TDS-004 §10 — D-01 open | Class 2 ±15% | |
| 1.3 | Shredder Train — Modules 1–7 | See TDS-003 §10 | Class 2 ±15% | |
| 1.4 | PRE-LFB-001 — Liquifact Collection Buffer | OPEN — TDS-005 | — | |
| 1.5 | PRE-EVP-001 — Liquifact Evaporators (2× redundant) | OPEN — TDS-005 | — | |
| 1.6 | PIMB Structure — Integrated | OPEN — D-66 | Class 2 ±15% | |
| 1.7 | NEXUS — PIMB overhead (Z1/Z2/Z3/Z4) | OPEN — D-66 | — | |
| 1.8 | Zero-E PowerBlock™ — PIMB draw portion | OPEN — ZEP TDS | — | |
| 1.9 | APS Equipment — PIMB fans, ductwork, capture manifold | OPEN — APS TDS | — | |
| 1.10 | SCADA / Controls — PIMB | OPEN | — | |
| TOTAL TIC — Pregenesis Protocol | OPEN | Class 2 ±15% | ||
Included in TIC: All Pregenesis module equipment, ASI packaging and skid fabrication, FAT, Unitized Warranty Passport issuance, first-fill spares per §17.
Excluded from TIC: Site foundation (Owner scope), site utilities to NEXUS boundary (Owner scope), PIMB site preparation and earthworks (Owner scope), operator training beyond SAT witnessing.
12. Lead Time Schedule
Critical Path
D-ASI-01 resolution → ASI award → procurement package issue → hydraulic drawbridge fabrication (24–36 weeks) → FAT → module delivery. No purchase order authorized until D-ASI-01 closes.| WBS | Equipment / Action | Lead Time | Priority |
|---|---|---|---|
| — | D-ASI-01 — ASI Vendor Selection + Award | OPEN | Blocks ALL procurement |
| — | D-01 — T2-ITD OEM Sizing (LCI Corp RFQ) | OPEN | Blocks T2-ITD PO |
| 1A | TISAB/EASB Rigid Frame Buildings | 16–20 wks | Medium |
| 1B | Hydraulic Drawbridges (all 4 pairs) | 24–36 wks | Critical Path — first article risk |
| 1C | Truck Weighbridges (NTEP certified) | 12–16 wks | Low |
| 1D | Walking Floor Systems | 14–18 wks | Low |
| 2A | T2-ITD — Indirect Thermal Dryer (2 units) | OPEN — D-01 | Critical |
| 2B | Decanter Centrifuges (Alfa Laval ALDEC) | 16–22 wks | Medium |
| 2C | T2 Lumpbreakers + ASI-ISO-LBK-001 | 12–16 wks | Low |
| 2D | VRM / Impact Mill — T2 (Gebr. Pfeiffer) | 20–28 wks | Medium — grindability test required |
| 3A | Primary Shredders (2×, Vecoplan preferred) | 20–28 wks | Medium |
| 3B | Tire Pre-Shredders (2 units) | 16–22 wks | Medium |
| 3C | Hammermills — SHRD-HMR (2×) | 14–20 wks | Medium |
| 3D | VRM Enhancement Admix Pulverizer | 20–28 wks | Medium |
| 3E | Rotational Mixers — SHRD-MXR (2×) | 12–16 wks | Low |
| 3F | Feed Metering Bins — SHRD-RFB (2×) | 10–14 wks | Low |
| 4A | PRE-LFB-001 — Liquifact Collection Buffer | OPEN — TDS-005 | Medium |
| 4B | PRE-EVP-001 — Liquifact Evaporators (2×) | OPEN — TDS-005 | Medium |
| ASI | ASI Skid Fabrication + FAT (all modules) | 12–20 wks | After equipment receipt at ASI facility |
13. TRL / ERL / IRL Assessment
| Module Group | TRL | ERL | IRL | Notes |
|---|---|---|---|---|
| Modules 0A/0B/0C/0D | 8–9 | 7 | 6 | Equipment TRL=9. Custom hydraulic drawbridge TRL=7 — ACM tipping floor is novel. IRL=6 — D-11 connector open. |
| Shredder Train (1–7) | 9 / 5–6 (EAF) | 6 | 5 | Equipment TRL=9. EAF blending TRL=5–6 — no MCR analog at scale. IRL=5 — Regenesis ICD primary limiter. |
| T2 Processing | 8–9 / 6 (WHSG ICD) | 6 | 5 | T2-ITD TRL=8. D-THM-01 CLOSED PARAMETRIC. IRL=5 — WHSG cross-protocol ICD improving. |
| PRE-LFB-001 / PRE-EVP-001 | OPEN | OPEN | OPEN | TDS-005 not produced. Evaporator TRL expected 8–9. |
| Master Architecture Integration | — | 5 | 3 | IRL=3 — Regenesis ICD incomplete. RFH demand signal protocol open. |
14. Confidence Factor
| Assessment | Score | Condition |
|---|---|---|
| Master Architecture — Adjusted Confidence | ~68–70% | CONDITIONAL — Recovers to 75–78% upon: D-ASI-01 ASI award, D-THM-01 WHSG parameters confirmation (now parametric), TDS-005 production. D-65 LOCKED Session 7 — partial recovery achieved. Re-score at OER Gate 2. |
Confidence Limiter
D-65 is now LOCKED Session 7 (CSC thermal = MCR hot process gas direct integration). D-35 CLOSED PARAMETRIC (2–8 MW NXS-Z2 at 400 TPD — revised 345 TPD basis in Session 9). Risk severity reduced; remaining drag from D-ASI-01 and TDS-005 gap.15. Availability Model
| Equipment / Subsystem | MA (%) | MTBF (hrs) | MTTR (hrs) |
|---|---|---|---|
| Module 0A — TISAB (2× weighbridges, N+1) | 99.5 | 8,760 | 4 |
| Module 0B — Hydraulic Drawbridges (2× per trough, 50% duty) | 92–95 | 2,000–3,000 | 8–12 |
| Module 0B — Walking Floors (2× per trough, 50% duty) | 96–98 | 4,000–6,000 | 4–8 |
| Module 0D — LBS Pumps (2× PC pumps, 50% duty) | 96–98 | 3,500–5,000 | 4–6 |
| Modules 0A/0B/0C/0D — System OA | 94–96 | — | — |
| Primary Shredder — SHRD-SHR (2×, 50% duty) | 88–92 | 350–500 | 8–16 |
| Hammermill — SHRD-HMR (2×, 50% duty) | 90–94 | 500–800 | 6–12 |
| Enhancement Admix VRM (2×, 50% duty) | 92–96 | 1,000–2,000 | 8–16 |
| Shredder Train — System OA | 92–95 | — | P50: 940 TPD · P90: 900 TPD |
| Decanter Centrifuge (2×, 50% duty) | 94–97 | 2,000–4,000 | 6–12 |
| T2-ITD (2×, 50% duty) | 93–97 | 2,500–4,000 | 8–16 |
| T2 Lumpbreakers (2×, 50% duty) | 95–98 | 3,000–5,000 | 4–8 |
| T2 Processing — System OA (WHSG-dependent) | 91–95 | — | — |
| PRE-EVP-001 (redundant pair) | OPEN — TDS-005 | — | — |
| PREGENESIS PROTOCOL — MASTER OA | 91–95% | — | Governed by T2 Processing (WHSG-dependent) |
16. Risk Register
| Risk ID | Category | Severity | Mitigation |
|---|---|---|---|
| R-01 | D-ASI-01 — ASI vendor not selected | HIGH | Competitive RFQ to ≥3 qualified ASI candidates per ARM-2026-002 American Manufacturing Preference Policy. No procurement until ASI awarded. |
| R-02 | D-65 → D-35 → WHSG → T2-ITD thermal supply chain | REDUCED | D-65 LOCKED Session 7: CSC thermal = MCR hot process gas. D-35 CLOSED PARAMETRIC. Re-assess at OER Gate 2. |
| R-03 | Regenesis ICD incomplete — RFH demand signal & WHSG steam parameters | HIGH | D-THM-01 CLOSED PARAMETRIC (200–400°C / 10–40 bar). ICD-WHSG-T2ITD-001 in CBT-PRE-ICD-001 Rev 2. RFH demand signal protocol still open. |
| R-04 | Enhancement Admix grindability — SHRD-APZ + T2 VRM cross-module risk | MEDIUM | Parallel grindability tests with Gebr. Pfeiffer before OER Gate 2. 20% installed power margin. |
| R-05 | SCADA vehicle manifest — ECN-A02 not formalized | MEDIUM | Formalize ECN-A02 before SHRD-RFB controls ordered. Hard interlock: COMPRESSION flag ≠ bridge bay. |
| R-06 | PIMB footprint discrepancy — TDS-001 vs ECN-002 Rev 1 | MEDIUM | Reconcile before foundation design. D-66 open. ECN-A03 if footprint change required. |
| R-07 | TDS-005 gap — PRE-LFB-001 and PRE-EVP-001 undocumented | MEDIUM | Produce TDS-005 as next Pregenesis TDS priority. Until then, treat as unspecified in TIC. |
| R-08 | D-23 — PRE-LFB-001 buffer hold time unresolved | LOW | Resolve D-23 in TDS-005. Notify Regenesis Ops immediately on dual EVP fault. |
17. Spares Register
Master Criticality A/B/C spares consolidated from child TDS documents. Criticality A items must be physically stocked on site at FAT acceptance. All items with lead times >12 weeks must be ordered ≥16 weeks before planned Maintenance Interval. Only items from the ASI-issued Authorized Spares Catalog qualify for warranty-preserving replacement.
| Crit. | Source | Item | First Fill | Operating |
|---|---|---|---|---|
| A | TDS-002 | Hydraulic drawbridge cylinder seals (all 4 trough pairs) | 1 full set | 0.5 set/yr |
| A | TDS-002 | Walking floor hydraulic seals — Trough 2 (Viton/PTFE) | 2 full seal sets | 1 set/yr |
| A | TDS-002 | TISAB/EASB door bottom seals (all positions) | 16 sets | 8 sets/yr |
| A | TDS-002 | Module 0D LBS pump rotor/stator (PC pumps) | 2 sets | 1 set/yr |
| A | TDS-003 | Primary Shredder rotor tools — SHRD-SHR (50% installed count) | 1 change-out set/unit | Annual order |
| A | TDS-003 | Hammermill hammers and liners — SHRD-HMR (25% per unit) | 25% set/unit | Per wear rate |
| A | TDS-003 | VRM wear segments — SHRD-APZ grinding rollers and table | 1 full change-out set | Annual order |
| A | TDS-004 | Decanter centrifuge scroll hard-facing — T2-DCN | 2 scroll sets | 1 set/18 months |
| A | TDS-004 | T2-ITD thermal seal and rotor wear components | 1 full set/unit | Per OEM PM schedule |
| A | TDS-004 | ASI-ISO-LBK-001 neoprene isolation pads (per lumpbreaker) | 2 full pad sets | Per degradation |
| B | TDS-002 | AR400 head-end wear plates (per trough) | 2 sets | 1 set/2 yr |
| B | TDS-002 | Trough 1 AR400 wall liner panels (10% area) | Per install qty | 1 set/3 yr |
| B | TDS-003 | TPS hook-type rotor tools (25% per unit) | 25% set/unit | Per wear |
| B | TDS-003 | MFS magnetic belt (per MFS unit) | 1 spare/unit | Per failure |
| B | TDS-004 | VRM grinding roller wear segments — T2 | 1 full set | 1 set/18 months |
| C | TDS-002 | RFID reader heads (all TISAB positions) | 2 spare heads | Per failure |
| C | TDS-003 | Conveyor belts — SHRD-CV series | 1 spare/conveyor | Per wear |
| C | TDS-004 | Polymer dosing pump diaphragms — T2-PCM-001 | 4 diaphragms | Per failure |
| — | TDS-005 (OPEN) | PRE-LFB-001 / PRE-EVP-001 Criticality A spares | OPEN | OPEN |
18. Warranty Register
Guarantee Conditionality Statement
All throughput, performance, and availability guarantees apply when: (1) Manufacturing Feedstock is within the P90 design envelope; (2) utilities are provided at specification; (3) operation follows OPS procedures; (4) Planned Maintenance Intervals are adhered to; and (5) the Authorized Strategic Integrator (ASI) has completed Factory Acceptance Testing and issued the Unitized Warranty Passport for each serial-numbered module.D-ASI-01 Open
Warranty administration framework defined here. Named ASI will be inserted at D-ASI-01 close by ECN. All references to "ASI (vendor pending D-ASI-01)" updated at award.| Equipment Group | Warranty Period | OEM Guarantee | Source |
|---|---|---|---|
| TISAB/EASB Rigid Frame Buildings | 25 yr frame / 20 yr panel / 5 yr door mechanism | Yes — OEM | TDS-002 §18 |
| Hydraulic Drawbridges | 24 mo from FAT | Throughput performance guarantee | TDS-002 §18 |
| Walking Floor Systems | 18 mo from FAT | Yes — OEM manufacturer | TDS-002 §18 |
| Module 0D — LBS Station | 18 mo from FAT | Yes — OEM (PC pump) | TDS-002 §18 |
| T2-ITD — Indirect Thermal Dryer | 24 mo from FAT | Thermal performance — pending D-01 OEM confirmation | TDS-004 §18 |
| Decanter Centrifuges | 24 mo from FAT | Yes — Alfa Laval standard industrial | TDS-004 §18 |
| Shredder Train (complete — Modules 1–7) | 18 mo from FAT | Throughput guarantee — P90 900 TPD / 72-hr TPGT | TDS-003 §18 |
| PRE-LFB-001 / PRE-EVP-001 | OPEN — TDS-005 | OPEN | TDS-005 pending |
| NEXUS Modular Utilities Interconnect | Per CBT-NXS-TDS-001 Rev 0 §18 | Yes — ASI Unitized Warranty Passport | CBT-NXS-TDS-001 |
| Zero-E PowerBlock™ | Per CBT-ZEP-TDS-001 Rev 0 §18 | Yes — ASI Unitized Warranty Passport | CBT-ZEP-TDS-001 |
END OF DOCUMENT — CBT-PRE-TDS-001 | Rev 2 | April 2026 | CONFIDENTIAL — CARBOTURA INC. — ALL RIGHTS RESERVED
RevCon 3 Performance Baseline | Authorized Strategic Integrator (ASI) Integration Model | Class 2 OER ±15%
RevCon 3 Performance Baseline | Authorized Strategic Integrator (ASI) Integration Model | Class 2 OER ±15%