Pregenesis Protocol β Technical Design Specification
Modules 0A, 0B & 0C
Truck Intake & Scale Airlock, Dumping Floor & Trough System, Exit Airlock Scale Building
Complete feedstock reception system β TISAB, Dumping Floor, dual troughs, EASB
Document Control
| Document Number | CBT-PRE-TDS-002 |
| Revision | Rev 1 β April 2026 |
| OER Classification | Class 2 (Β±15%) OEM Engineering Release β equivalent to "FEED / DOE FEL-3" [external regulatory reference β DOE LPO / AACE 18R-97 only] |
| Status | Issued for Review β PE Sign-Off / Investor Bill of Sale |
| Owner | Carbotura Inc. β Engineering |
| Quality Standard | ISO 9001:2015 |
| Authorized Strategic Integrator (ASI) | Role open to qualified ASI candidates per CBT-ASI-QUAL-001. RK Industries previously referenced β designation pending final partnership execution. |
| RevCon Performance Baseline | RevCon 3 β $150Mβ$325M/yr revenue floor, 400 TPD baseline factory |
| Chairman | Allen Witters |
Revision History
| Rev | Date | Author | Description |
|---|---|---|---|
| 0 | April 2026 | Carbotura Engineering | Initial Issue β Class 4 Preliminary (Β±30%). All ICDs status TBD. |
| 1 | April 2026 | Lead Systems Architect / OEM Engineering Director | Class 2 OER Upgrade. All ICD entries resolved per CBT-PRE-ICD-001 Rev 1. ASI terminology applied. Terminology Firewall v1.0 enforced. Skid-Integrated Spring Isolation references added via ICD package. RevCon 3 performance baseline confirmed. |
Table of Contents
- Executive Summary
- Facility Context & Module Boundaries
- Process Description
- Feedstock Design Envelope
- Module Equipment Specifications
- APS Interface Register
- Modular Installability & Interface Control (ICD Table)
- Utilities Register
- Vendor Matrix
- CAPEX Estimate
- TIC WBS Reconciliation
- Lead Time Schedule
- TRL / ERL / IRL Assessment
- Confidence Factor
- Availability Model
- Risk Register
- Spares Register
- Warranty Register
1. Executive Summary
DIAG-PRE-001
Pregenesis Protocol β Material Flow Overview
Process Flow
Module 0A Β· TISAB
Truck Arrival
RFID + Manifest
RFID + Manifest
β
NTEP Weighbridge
Gross Weight Β±20 lb
Gross Weight Β±20 lb
β
Airlock Hold
15 sec Β· β0.02 in. WC
15 sec Β· β0.02 in. WC
β
Module 0B Β· Dumping Floor
Bay Assignment
LED Signage
LED Signage
β
Hydraulic Bridge
45β70Β° Raise
45β70Β° Raise
β
Trough 1
MSW + Tires
MSW + Tires
β
Trough 2
Sludge + Ash
Sludge + Ash
β
Shredder Train Β· Modules 1β4
Tire Pre-Shredder
β
Primary Shredder
SHRD-SHR-001/002 Β· 380 kW
SHRD-SHR-001/002 Β· 380 kW
β
MFS Stage 1
Bulk Ferrous β FCB-001/002
Bulk Ferrous β FCB-001/002
β
Hammermill
P80 β€25 mm
P80 β€25 mm
β
MFS Stage 2
Fine Wire β FCB-003/004
Fine Wire β FCB-003/004
β
Rotational Mixer
AFR = 0.25 Β· CV <5%
AFR = 0.25 Β· CV <5%
β
Regenesis Feed Bin
β
Output
To Regenesis MCR
Blended Β· AFR 0.25 confirmed
Blended Β· AFR 0.25 confirmed
T2 Processing Β· Ash Path
NIR Moisture Sensor
Routing decision
Routing decision
β
Lumpbreaker
β
VRM Pulverizer
P80 <500 Β΅m Β· ATEX Z21
P80 <500 Β΅m Β· ATEX Z21
β
Ash Silo
ASL-001/002
ASL-001/002
β feeds Rotational Mixer
Also: Module 0C Β· EASB β Tare weight confirmation Β±5% Β· Load record close
Material flow from truck arrival through Pregenesis preparation to Regenesis MCR feed. APS Capture Stream runs parallel to all enclosed process zones (not shown for clarity).
DIAG-PRE-002
TISAB / EASB Airlock β 8-State Door Interlock Machine
State Machine
[*] Power Up
Raise request + interlocks clear
S0 β Both Doors Closed
Standby
Standby
Raise request + interlocks clear
S1 β Entry Door Opening
Entry door fully open
S2 β Truck Entering Β· On Scale
Truck on scale confirmed
S3 β Entry Door Closing
Entry door sealed
S4 β AIRLOCK HOLD
β0.02 to β0.05 in. WC Β· NTEP weight captured Β· Load acceptance confirmed
β0.02 to β0.05 in. WC Β· NTEP weight captured Β· Load acceptance confirmed
Weight captured + acceptance confirmed
S5 β Exit Door Opening
Exit door fully open
S6 β Truck Exiting Floor
Truck clear + dump body down
S7 β Exit Door Closing Β· Lane Reset
Exit door sealed β return to S0
β©
State machine governs both Lane A and Lane B independently. No door movement permitted outside this logic. STATE 4 (Airlock Hold) is the only state where negative pressure equalization and weighing occur.
Document Boundary Statement
This Technical Design Specification defines module-level technical requirements, interfaces, testing, and warranty boundaries only; commercial risk allocation, financing structures, delivery arrangements, and lender requirements are addressed in separate contractual and financing documents.Manufacturing Classification Statement
This Technical Design Specification 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 intake system is engineered as a closed-loop manufacturing subsystem designed for near-zero emissions, near-zero discharge, and near-zero residual. This design intent is achieved through enclosed material handling, continuous negative-pressure operation, internal capture of all airborne particulates and vapors via the APS Capture Stream, and the absence of routine wastewater discharge or disposal pathways. Environmental performance outcomes are contingent on execution at commercial scale and will be validated through SAT and FPT procedures.This TDS defines the engineering requirements for the Pregenesis feedstock intake, receiving, and trough feed system. It covers Manufacturing Feedstock reception through the Truck Intake & Scale Airlock Building (TISAB β Module 0A), feedstock receiving on the Dumping Floor (Module 0B) with dual-trough material routing, and truck exit through the Exit Airlock Scale Building (EASB β Module 0C). Trough 2 walking floor connection to the T2 processing train (Module T2, detail in CBT-PRE-TDS-004) is also defined within this document boundary.
Together, Modules 0A, 0B, and 0C constitute the complete feedstock reception system upstream of the Pregenesis Shredder Train (CBT-PRE-TDS-003). The system is designed for 1,000 TPD (as-received) per trough, with full N+1 redundancy on all walking floor and conveyor equipment. Both troughs operate independently at full 1,000 TPD nameplate capacity. The TISAB and EASB buildings provide a 4-hour surge buffer at design throughput.
All three modules maintain a continuous negative-pressure boundary (β0.05 to β0.10 in. WC throughout the Dumping Floor; β0.02 to β0.05 in. WC at TISAB/EASB airlocks), ensuring air flows inward from atmosphere at all times. No routine atmospheric discharge occurs from any module in this group. The Atmospheric Protection System (APS) recovers all airborne particulates and vapors as product streams per CBT-APS-TDS-001.
2. Facility Context & Module Boundaries
2.1 Module Position in Facility
Modules 0A, 0B, and 0C form the front-end of the Pregenesis Protocol. TISAB (0A) is the entry pressure boundary; the Dumping Floor (0B) is the central receiving area with dual troughs; EASB (0C) is the exit pressure boundary. All three modules maintain a continuous negative-pressure boundary ensuring air flows inward from atmosphere at all times.
| Boundary | Description | Reference |
|---|---|---|
| Upstream | Facility perimeter / public road (truck arrival) | N/A β facility boundary |
| Downstream (Trough 1) | Lift conveyor discharge to Primary Shredder feed hopper | CBT-PRE-TDS-003 |
| Downstream (Trough 2) | Walking floor discharge to Trough 2 Processing train | CBT-PRE-TDS-004 |
| Excluded: Shredder Train | Modules 1β6 size reduction, ferrous separation, blending | CBT-PRE-TDS-003 |
| Excluded: T2 Processing | Trough 2 thermal drying and pulverizing to <500 Β΅m | CBT-PRE-TDS-004 |
| Excluded: APS System | APS design (fans, filters, ducts, product recovery) | CBT-APS-TDS-001 |
2.2 Input Register
| Input Stream | Source | Routing | Notes |
|---|---|---|---|
| Manufacturing Feedstock (MSW / tires) | Inbound trucks via TISAB | Trough 1 | Primary Pregenesis Manufacturing Feedstock stream |
| Sludge / ash | Inbound trucks via TISAB | Trough 2 | Sludge and ash to T2 Processing |
| Electrical power | Site utility / 32 MW PowerBlock | All modules | 480V 3-phase 60 Hz; main service 4,160V or 13.8 kV |
| Compressed air | Site compressors | All modules | 100 psig β door actuators, instruments, controls |
| SCADA facility management signal | Facility SCADA master | All modules | Bay assignment, throughput demand, payload reconciliation |
2.3 Output Register
| Output Stream | Destination | Rate | Notes |
|---|---|---|---|
| Shredded feedstock to Shredder Train | Trough 1 lift conveyor to Primary Shredder | ~985β995 TPD | After magnetic head pulley ferrous removal |
| Ash/sludge stream to T2 Processing | Trough 2 walking floor to T2 train | 1,000 TPD | Leachate accounted separately |
| Ferrous metals | Ferrous collection bin | ~0.5β1.5% of Trough 1 flow | Magnetic head pulley on Trough 1 lift conveyor |
| APS Capture Streams (all enclosures) | APS (CBT-APS-TDS-001) | ~2,200 CFM normal | Process-capture basis; no dilution air |
| Leachate | Water treatment module | Variable | Trough 2 sump β designed for near-zero discharge |
| Confirmed payload data (SCADA) | Facility SCADA / billing system | Per truck | TISAB gross vs EASB tare reconciliation |
3. Process Description
3.1 Narrative Overview
Trucks arrive at the TISAB, pass through a two-lane airlock with certified weighbridge, tip their loads on the Dumping Floor, and exit via the EASB mirror airlock. The TISAB/EASB airlock system maintains the facility negative pressure boundary at all times β air always flows inward from atmosphere. The airlock interlock prevents both the entry and exit doors of any lane from being simultaneously open, preserving the pressure differential. RFID transponder readers at TISAB entry capture truck identification and are matched to EASB tare weight for payload reconciliation.
The Dumping Floor contains two parallel troughs running lengthwise. Trough 1 receives Manufacturing Feedstock (MSW and tires); hydraulic drawbridges raise to allow tipping directly into the trough. A walking floor system at the trough base meters material to a lift conveyor feeding the Shredder Train. Trough 2 receives sludge and ash with identical architecture routing to the Trough 2 Processing train. Bay assignment via SCADA LED signage routes each truck to the correct trough based on load manifest data.
3.2 Process Flow
| Step | Module | Action | Key Parameter |
|---|---|---|---|
| 1 | TISAB | Truck arrives β RFID tag read at lane entry | EPC tag capture |
| 2 | TISAB | Airlock hold β pressure equalization | β0.02 to β0.05 in. WC vs. outside |
| 3 | TISAB | Weighbridge measures gross weight | Β±20 lb legal-for-trade (NTEP) |
| 4 | TISAB | Exit door opens, truck enters Dumping Floor | SCADA bay assignment signal |
| 5 | Dumping Floor | Bay assignment via LED signage β Trough 1 or 2 | Load manifest match confirmed |
| 6 | Dumping Floor | Hydraulic bridge raises | <60 sec raise cycle |
| 7 | Dumping Floor | Truck tips Manufacturing Feedstock into trough | Gravity discharge; all material confined to trough |
| 8 | Dumping Floor | Bridge lowers; truck proceeds to EASB | <60 sec lower cycle |
| 9 | EASB | Airlock hold β pressure equalization | β0.02 to β0.05 in. WC vs. outside |
| 10 | EASB | Tare weight confirmed | Β±20 lb legal-for-trade |
| 11 | EASB | Payload reconciliation (gross β tare = net) | Β±5% reconciliation tolerance |
| 12 | EASB | Truck exits β RFID load record closed | Load record archived to SCADA |
3.3 Mass Balance
| Stream | Trough | Design Rate (TPD) | Notes |
|---|---|---|---|
| MSW + tires input | Trough 1 | Up to 1,000 | P90 envelope includes 100% tires by day |
| Sludge + ash input | Trough 2 | Up to 1,000 | Moisture 60β85% sludge; 5β30% ash |
| Output to Shredder Train | Trough 1 lift conveyor | ~985β995 | After magnetic head pulley ferrous removal (~0.5β1.5%) |
| Output to T2 Processing | Trough 2 walking floor | 1,000 | Leachate volume accounted separately in T2 mass balance |
| Ferrous metals removed | Trough 1 magnetic head pulley | ~5β15 | Estimated 0.5β1.5% of MSW+tire stream; co-manufactured revenue stream |
| Total system input (combined) | Both troughs | Up to 2,000 | Full dual-trough design capacity |
3.4 Key Process Parameters
| Parameter | Value | Basis |
|---|---|---|
| Building negative pressure | β0.05 to β0.10 in. WC | Relative to TISAB/EASB interior |
| TISAB/EASB pressure | β0.02 to β0.05 in. WC | Relative to outside atmosphere |
| Airlock cycle time target | <3 minutes per truck | Door close + verify + door open sequence |
| Trough 1 capacity (design) | 1,000 TPD | MSW + tire Manufacturing Feedstock |
| Trough 2 capacity (design) | 1,000 TPD | Sludge + ash streams |
| Drawbridge raise/lower cycle | <60 seconds | Full travel; hydraulic drive |
| Surge buffer (trough) | 4-hour supply at design throughput | ~167 tons at 1,000 TPD |
| Walking floor speed | 0β12 ft/min variable | SCADA-controlled via proportional hydraulic valve |
| Payload reconciliation tolerance | Β±5% | TISAB gross vs EASB tare; pass/fail threshold |
| Truck throughput (design) | 60+ trucks/hour per direction | 2 lanes Γ 30 trucks/hr per lane |
4. Feedstock Design Envelope
Guarantee Conditionality
All throughput and equipment performance guarantees apply when Manufacturing Feedstock is within the P90 design envelope defined below, utilities are provided at specification, and operators follow OPS procedures. Any Li-battery detection in an inbound load triggers immediate quarantine; no-tip protocol applies until visual inspection clears the load.4.1 Trough 1 β MSW & Tire Feedstock Design Envelope
| Component | P50 Range (wt%) | P90 Design Max (wt%) | Design Consideration |
|---|---|---|---|
| Paper / Cardboard | 20β28% | 35% | High cellulose; manageable via walking floor |
| Plastics (mixed) | 12β18% | 22% | Mixed polymers; no special handling required |
| Food organics | 20β35% | 42% | High moisture; contained by negative pressure + APS |
| Yard waste | 5β15% | 20% | Seasonal variation; lignocellulosic bulk |
| Ferrous metals | 3β6% | 8% | Recovered at magnetic head pulley on lift conveyor |
| Non-ferrous metals | 1β3% | 4% | Pass-through to Shredder Train |
| Glass / ceramics | 3β6% | 8% | Inert; manageable with AR400-lined trough |
| Textiles / Rubber | 2β6% | 10% | Rope/textiles can bridge β walking floor handles |
| Whole tires | 0β10% | 40% | Bridge-tip directly; tires 100% by day acceptable |
| Li-ion batteries | Trace | ANY DETECTION | Quarantine protocol β thermal camera required at TISAB approach |
4.2 Prohibited Materials
| Material | Hazard | Detection Method | Protocol |
|---|---|---|---|
| Li-ion / Li-polymer batteries | Thermal runaway / fire | Fixed thermal camera at truck approach | Quarantine bay β load rejected before tipping |
| Pressurized cylinders (any gas) | Explosion | Visual inspection + operator notification | Reject at gate; do not permit entry |
| Radioactive materials | Radiation | Fixed portal radiation detector at TISAB entry | Immediate quarantine; emergency protocol |
| Liquid in bulk containers | Leachate, fire | Visual + RFID manifest check | Reject at gate unless classified as approved sludge stream |
| Medical / sharps waste | Biohazard | Manifest review | Reject β not accepted as Manufacturing Feedstock |
5. Module Equipment Specifications
5.1 TISAB β Truck Intake & Scale Airlock Building TISB-BLD-001/002
TISAB β Truck Intake & Scale Airlock Building TISB-BLD-001/002
Building Type
Sprung Structure fabric building on reinforced concrete slab
Configuration
2 parallel drive-through lanes, fully enclosed
Lane Dimensions
18 ft wide Γ 90 ft long per lane
Total TISAB Footprint
~50 ft Γ 100 ft (including wall thickness and service access)
Ceiling Height (clear)
22 ft minimum β accommodates loaded semi-trailer clearance
Doors Per Lane
2Γ automatic high-speed insulated roll-up doors (4 doors total)
Door Dimensions
16 ft W Γ 16 ft H clear opening per door
Door Cycle Rating
Minimum 50,000 cycles/year
Door Interlock
Entry door must fully close and seal before exit door opens β true airlock sequence
Weighbridge Type
In-ground certified legal-for-trade weighbridge, pit-mount, per NIST Handbook 44
Weighbridge Capacity
100,000 lb (legal-for-trade NTEP certified)
Weighbridge Accuracy
Β±20 lb
Weighbridge Platform
70 ft L Γ 11 ft W per lane β full semi-trailer wheelbase
RFID/Transponder
Passive UHF RFID readers at lane entry β industrial weatherproof grade
Airlock Cycle Time
<3 minutes per truck (door close + verification + door open)
Pressure Differential
β0.02 to β0.05 in. WC relative to outside atmosphere
APS Capture (Normal)
400 CFM β process-capture basis; no dilution air
APS Capture (Peak)
700 CFM β during peak truck traffic and door cycling
Estimated CAPEX
$800Kβ$1.5M per building [Class 2 Β±15%]
5.2 Trough 1 β MSW & Tires DUMP-TR1-001
Trough 1 β MSW & Tire Manufacturing Feedstock DUMP-TR1-001
Function
Receive MSW and tire Manufacturing Feedstock; meter to Shredder Train via lift conveyor
Dimensions
12 ft wide Γ 200 ft long Γ 16 ft deep (clear inside)
Surge Buffer (design)
4-hour supply at 1,000 TPD = ~167 tons at 425 lb/ydΒ³ average MSW density
Wall Liner
AR400 abrasion-resistant steel plates, 3/8-in. thick, bolt-on replaceable panels
Walking Floor Type
Reciprocating slat walking floor conveyor (hydraulic drive)
Walking Floor Qty
2 units at 50% duty cycle β each rated 1,000 TPD full throughput
Walking Floor Speed
0β12 ft/min variable, SCADA-controlled via proportional hydraulic valve
Lift Conveyor Type
2Γ enclosed belt conveyor, fire-resistant NFPA rated, heavy-duty chevron/cleated belt
Lift Conveyor Capacity
1,000 TPD per unit; 1,500 TPD surge capacity
Lift Conveyor Inclination
18β22 degrees
Magnetic Head Pulley
Rare-earth permanent magnet; continuous ferrous removal at conveyor discharge; est. 0.5β1.5% of stream
5.3 Hydraulic Drawbridge System DUMP-HDB-xxx
Hydraulic Drawbridge System β Both Troughs DUMP-HDB-xxx
Quantity
2 hydraulic lift bridges per trough (4 total)
Load Rating
80,000 lb GVW minimum; 100,000 lb design load
Structural Frame
W-section steel beams, galvanized; designed per AASHTO HL-93 + 25% dynamic factor
Raise/Lower Cycle
<60 seconds full travel
Safety β Wheel Chock
Pneumatic/electronic wheel chock engagement confirmed before bridge raise initiates
Safety β Personnel
Laser curtain / photo-eye array confirms no personnel beneath bridge β Class IV per ANSI/NFPA 79
Emergency Stop
E-stop pull cords both sides of each bridge; mushroom-head E-stop at each HPU; SCADA alarm logged
Estimated CAPEX
$300Kβ$600K per pair (2 bridges per trough) β custom fabrication; performance-specified [Class 2 Β±15%]
6. APS Interface Register
APS Process-Capture Basis Statement
CFM figures are process-capture basis only. No dilution air, comfort ventilation, or regulatory dispersion airflow is included. All APS Capture Stream flows represent product streams being recovered or contaminated air managed internally. APS system design is specified in CBT-APS-TDS-001.| Module | APS Capture Point | Normal CFM | Peak CFM | Temp (Β°C) | Material | Recovery Value |
|---|---|---|---|---|---|---|
| TISAB (0A) | Ceiling duct β building | 400 | 700 | Ambient | Coarse particulate, minor biogas | Carbon fines to recovery |
| Trough 1 (0B) | Open-top duct pickup | 600 | 1,000 | Ambientβ35 | MSW particulate, biogas traces, rubber dust | Carbon fines; biogas to APS recovery |
| Trough 2 (0B) | Open-top duct pickup | 500 | 900 | Ambientβ45 | Sludge vapors, ash particulate, HβS | Condensate to water treatment; dry fines to recovery |
| Dumping Floor general | Building envelope ceiling plenum | 300 | 500 | Ambient | General building air, minor fugitive particulate | General containment |
| EASB (0C) | Ceiling duct β building | 400 | 700 | Ambient | Coarse particulate, minor biogas from empty trucks | Carbon fines to recovery |
| TOTAL β 0A/0B/0C | All capture points combined | ~2,200 | ~3,800 | β | Combined process-capture stream | Per individual stream above |
7. Modular Installability & Interface Control
All Pregenesis sub-modules are delivered as factory-assembled, pre-wired, and pre-tested units designed for Modular Assembly upon delivery. Field activities are limited to module placement, standardized mechanical and electrical interconnections, and verification testing per SAT and FPT procedures. All interfaces use RK Industries ASI Standardized Connectors per CBT-PRE-ICD-001 Rev 1.
ICD Rev 1 β Zero TBD Entries
All six ICD entries for Modules 0A/0B/0C have been fully resolved in CBT-PRE-ICD-001 Rev 1. Interface Readiness Level (IRL) upgraded from IRL 3β4 (Rev 0) to IRL 5 (Rev 1). See the full ICD document: CBT-PRE-ICD-001 Rev 1 β| Interface | ICD Reference | Connection Type | Status |
|---|---|---|---|
| TISAB entry β Dumping Floor | ICD-TISB-DUMP-001 | Pressure boundary door + APS duct + Modbus TCP data | DEFINED β Rev 1 |
| Dumping Floor β EASB | ICD-DUMP-EASB-001 | Pressure boundary door + APS duct + Modbus TCP data | DEFINED β Rev 1 |
| Trough 1 lift conveyor β Shredder Train | ICD-DUMP-SHRD-001 | Flanged AR400 chute + E-stop SIL 1 + Modbus TCP feed rate | DEFINED β Rev 1 |
| Trough 2 feed conveyor β T2 Processing | ICD-DUMP-T2PR-001 | Flanged 316L SS chute + NIR analog + Modbus TCP routing | DEFINED β Rev 1 |
| All modules β APS | ICD-DUMP-APS-001 | 5Γ ASI-APS-FLG-6IN-RD + Rosemount 3051 DP + Modbus TCP | DEFINED β Rev 1 |
| TISAB/EASB β SCADA Master | ICD-TISB-SCADA-001 | Full Modbus TCP/IP I/O marshaling β weighbridge, RFID, doors, bay LED | DEFINED β Rev 1 |
SAT / FPT Statement
Site Acceptance Testing (SAT) and Full Performance Testing (FPT) will be conducted following module assembly and initial startup. A 72-hour continuous Throughput Performance Guarantee Test (TPGT) is required with Manufacturing Feedstock within the P90 envelope, witnessed by Carbotura Engineering, Owner's Engineer, and an independent third party.8. Utilities Register
8.1 Electrical Load Schedule
| Sub-Module | Equipment | Normal Load (kW) | Peak Load (kW) | Notes |
|---|---|---|---|---|
| TISAB (0A) | Doors, scales, RFID, lighting, controls | 35 | 60 | Primarily door motors and weighbridge controllers |
| Dumping Floor (0B) | Walking floors (2Γ T1 + 2Γ T2) | 120 | 240 | Walking floor HPU drives scale with throughput |
| Dumping Floor (0B) | Lift conveyors (2Γ Trough 1) | 80 | 160 | 2Γ 75 HP VFD motors at 50% duty |
| Dumping Floor (0B) | Bridge HPUs (4 sets) | 40 | 80 | Intermittent; 50 HP each during bridge cycle |
| Dumping Floor (0B) | Signage, lighting, controls, leachate pumps | 25 | 40 | LED lighting, SCADA controls, sump pumps |
| EASB (0C) | Doors, scales, RFID, lighting, controls | 35 | 60 | Mirror of TISAB electrical load |
| TOTAL β 0A/0B/0C | All sub-modules combined | ~335 kW | ~580 kW | At 1,000 TPD design throughput |
9. Vendor Matrix
9.1 Sprung Structure Buildings
| Vendor | Country | OEM Guarantee | Key Specs | Notes |
|---|---|---|---|---|
| Sprung Structures Inc. | Canada / USA | Yes β 10 yr structure, 5 yr fabric | Clear-span, automated roll-up doors, negative pressure capable, 22+ ft clearance | Industry leader; extensive industrial reference installations |
| ClearSpan Fabric Structures | USA | Yes β 50 yr structural | Custom clear-span, full-height roll-up doors, insulated fabric | Strong North American presence |
| Legacy Building Solutions | USA | Confirm at RFQ | Rigid frame clear-span, high-bay rated, custom door configurations | Steel rigid frame with fabric skin; heavy-duty industrial |
9.2 Truck Weighbridges
| Vendor | Country | OEM Guarantee | Key Specs | Notes |
|---|---|---|---|---|
| Mettler Toledo | USA / Global | Yes β 24 months parts + labor | Legal-for-trade, NTEP certified, pit-mount, SCADA integration | Global standard; full service network |
| Rice Lake Weighing Systems | USA | Yes β 24 months | Full range pit-mount legal-for-trade; SCADA integration | Strong USA dealer network; competitive pricing |
| Avery Weigh-Tronix | USA / UK | Yes β 24 months | OIML/NTEP dual-certified, pit-mount, SCADA/ERP ready | Global network; strong in regulated industrial applications |
10. CAPEX Estimate
AACE Classification β Class 2 (Β±15%) | 2026 USD
This capital cost estimate is classified as Class 2 (Β±15%) OEM Engineering Release per AACE International RP 18R-97. All values in 2026 USD. Estimating methodology: factored/parametric β equipment costs from budget quotes, ROM quotes, and industry benchmarks.| Line Item | Low Estimate | High Estimate | Basis |
|---|---|---|---|
| TISAB building (Sprung Structure + fitout) | $600K | $1.2M | Sprung structure + doors + slab + fire suppression |
| TISAB scales + weighbridge systems (2 lanes) | $120K | $250K | 2Γ NTEP-certified pit-mount scales + controllers |
| TISAB doors + controls + RFID | $80K | $150K | 4 doors, PLC interlocks, RFID readers, safety systems |
| Dumping Floor concrete Modular Assembly | $800K | $1.5M | Reinforced slab + push walls + floor drains |
| Trough 1 + AR400 liner | $400K | $800K | RC walls, AR400 steel liner panels, wheel guides |
| Trough 1 hydraulic bridges (2 sets) | $600K | $1.2M | Custom fabrication; AASHTO HL-93 rated; HPUs included |
| Trough 1 walking floors (2Γ) + lift conveyors (2Γ) + magnetic head pulley | $700K | $1.4M | Keith or equivalent; AR400 slats; hydraulic drive; enclosed belt NFPA |
| Trough 2 + 316L liner + sump | $500K | $1.0M | RC walls, 316L SS liner, leachate sump + tank + pumps |
| Trough 2 hydraulic bridges (2 sets) | $600K | $1.2M | Same as Trough 1 + corrosion upgrades |
| Trough 2 walking floors (2Γ, 316L) + feed conveyors (2Γ) | $550K | $1.1M | 316L SS slats + corrosion premium; screw/en-masse conveyors |
| EASB building + scales (mirror of TISAB) | $700K | $1.4M | Same spec as TISAB; 2 lanes, 4 doors, 2 scales, RFID |
| Thermal cameras + Li-battery detection | $80K | $150K | Fixed thermal cameras at TISAB approach; SCADA integration |
| Subtotal β Direct Equipment | $5.73M | $11.35M | Lines above |
| Electrical, instrumentation, controls (15%) | $860K | $1.7M | E&I at 15% of equipment subtotal β Class 2 basis |
| Modular Assembly labor (15%) | $860K | $1.7M | ASI assembly at 15% of equipment subtotal |
| Contingency (15%) | $1.12M | $2.21M | Applied per AACE Class 2 basis |
| TOTAL CAPEX β Modules 0A/0B/0C | $8.57M | $16.96M | Class 2 Β±15% | AACE 18R-97 | 2026 USD |
13. TRL / ERL / IRL Assessment
| Equipment / System | TRL | ERL | IRL | Assessment Notes |
|---|---|---|---|---|
| Sprung Structure buildings | 9 | 5 | 5 | Fully commercial; deployed at hundreds of industrial sites (Sprung/ClearSpan OEM data) |
| Certified truck weighbridges | 9 | 5 | 5 | Mature commercial technology; NTEP certification established standard |
| Reinforced concrete trough | 9 | 5 | 5 | Standard civil/structural; no novel technology |
| Walking floor systems | 9 | 5 | 5 | Established technology; 40+ year heritage in bulk solids (Keith Manufacturing operating records) |
| Hydraulic drawbridges | 7β8 | 4 | 4 | Custom adaptation of proven hydraulic bridge technology; performance-spec procurement; limited tipping floor reference |
| Lift conveyors + magnetic head pulley | 9 | 5 | 5 | Standard industrial belt conveyor; magnetic head pulley proven for ferrous separation |
| TISAB/EASB integrated airlock + pressure management | 6β7 | 3β4 | 5 | Novel integration of proven airlock and pressure control technologies; IRL upgraded to 5 in Rev 1 with full ICD definition |
| SCADA payload reconciliation | 8 | 4 | 5 | Weighbridge SCADA integration well-established; automated net payload reconciliation standard in WTE applications |
| OVERALL MODULE TRL | 7 | 4 | 5 | IRL upgraded Rev 0βRev 1 with full ICD definition |
14. Confidence Factor
| Factor | Weight | Score (0β10) | Weighted Score | Rationale |
|---|---|---|---|---|
| Technology maturity (TRL) | 25% | 8.5 | 2.13 | Most equipment TRL 9; hydraulic bridges TRL 7β8; integrated airlock TRL 6β7 |
| Engineering completeness (ERL) | 20% | 8.0 | 1.60 | ERL 4β5 on established equipment; Class 2 OER achieved Rev 1 |
| Integration readiness (IRL) | 15% | 9.0 | 1.35 | All ICDs fully defined Rev 1; IRL upgraded to 5 |
| Vendor availability & supply chain | 15% | 8.5 | 1.28 | Multiple qualified vendors for all categories |
| Operational heritage | 15% | 7.5 | 1.13 | Walking floors/conveyors well-referenced; integrated negative-pressure airlock facility is novel combination |
| Regulatory / permitting clarity | 10% | 7.5 | 0.75 | No novel regulatory pathway for standard equipment; facility-level permitting is site-specific |
| TOTAL CONFIDENCE SCORE | 100% | β | 8.24 / 10 = 82.4% | GOOD β Investor-bankable at Rev 1 Class 2 OER |
15. Availability Model
| Equipment | MA | MTBF (hr) | MTTR (hr) | Notes |
|---|---|---|---|---|
| TISAB/EASB roll-up doors | >98% | >5,000 | 1β2 | 2N redundancy; door motor replacement is maintenance task (OEM operating records) |
| Truck weighbridges | >99% | >10,000 | 1 | Highly reliable; load cell replacement if needed is fast (Mettler Toledo OEM data) |
| RFID reader systems | >99.5% | >15,000 | <1 | Solid-state; spare units on site |
| Hydraulic drawbridges | 92β95% | 1,000β2,000 | 2β4 | Custom hydraulic system; cylinder seal wear primary failure mode; critical path for system OA (calculated β industry hydraulic cylinder benchmark) |
| Walking floor systems | 94β97% | 2,000β4,000 | 2β4 | 50% duty cycle on 2Γ units; slat replacement is planned maintenance (Keith Manufacturing reference data) |
| Lift conveyors (Trough 1) | 96β99% | 3,000β6,000 | 1β3 | 50% duty cycle; belt and magnetic head pulley are planned maintenance items |
| Feed conveyors (Trough 2) | 95β98% | 2,500β5,000 | 1β3 | 316L SS screw conveyor; bearing and seal service in corrosive sludge environment |
| System OA β 0A/0B/0C | ~93% | β | β | Dominated by hydraulic bridge MA; N+1 walking floor/conveyor provides headroom. P50 throughput: 930 TPD avg. |
16. Risk Register
| Risk ID | Category | Severity | Mitigation |
|---|---|---|---|
| R-01 | Hydraulic bridge custom fabrication β schedule risk | MEDIUM | Critical path at 20β32 weeks. Early procurement decision. ICD finalization before fabrication release. Dual-source HPU components. |
| R-02 | Trough 2 sludge leachate β near-zero discharge compliance | MEDIUM | 316L SS liner + sump design. Duplex leachate pumps. Leachate tank sized for 4-hour peak. Route to water treatment at all times. |
| R-03 | Li-battery or pressurized container in Manufacturing Feedstock β fire risk at tipping | HIGH | Thermal cameras at TISAB approach for truck load screening. Quarantine bay protocol. Load rejection before tipping confirmed. NFPA fire suppression throughout building. |
| R-04 | Payload reconciliation discrepancy (>5%) β operational data quality | LOW | Regular NTEP re-certification annually. SCADA automated reconciliation with flagging. Manual override protocol for out-of-tolerance loads. |
| R-05 | NIR sensor accuracy for Trough 2 moisture routing | MEDIUM | Dual NIR sensors with cross-validation. Manual override available. SCADA trending to track sensor calibration drift. |
| R-06 | High-moisture sludge causing Trough 2 walking floor slippage | MEDIUM | 316L SS slat material. Ribbon-flight screw conveyor for cohesive sludge. SCADA alarm on low conveyor speed vs. demand. |
| R-07 | Pressure boundary loss (TISAB or EASB door failure) | MEDIUM | Redundant door interlocks. Pressure monitoring with SCADA alarm at β0.01 in. WC threshold. Automatic APS fan speed increase on pressure drop. |
18. Warranty Register
Guarantee Conditionality Statement
All throughput, performance, and availability guarantees apply when: (1) Manufacturing Feedstock is within the P90 design envelope defined in Section 4; (2) utilities are provided at specification per Section 8; (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.| Equipment | Vendor | Warranty Period | Coverage | Notes |
|---|---|---|---|---|
| Sprung Structure buildings | Sprung / ClearSpan / Legacy | 10 yr structure, 5 yr fabric | Structural frame and fabric covering | Door warranty is separate sub-contract with door OEM |
| Certified truck weighbridges | Mettler Toledo / Rice Lake / Avery | 24 months parts + labor | Load cells, summing box, controller, wiring harness | NTEP re-certification required annually regardless of warranty status |
| Walking floor systems | Keith / Hallco / Cargo Floor | 18 months | Slats, hydraulic cylinders, drive frame, control valves | Slat wear is a consumable β warranty covers manufacturing defects, not normal wear |
| Hydraulic drawbridges | Custom structural fabricator (ASI-qualified) | 24 months | Structural frame, hydraulic cylinders, HPUs, safety interlocks | Performance against spec must be verified at SAT |
| Lift conveyors | Superior / Fenner / Continental | 18 months | Belt, drive system, structural frame, magnetic head pulley | Belt warranty covers defects; wear from abrasive MSW is operational consumable |
| Feed conveyors β Trough 2 | Custom 316L SS fabricator (ASI-qualified) | 18 months | 316L SS screw flights, trough, bearings, seals, VFD drives | Corrosion warranty requires feedstock within Trough 2 design envelope |
END OF DOCUMENT β CBT-PRE-TDS-002 | Rev 1 | April 2026 | CONFIDENTIAL β CARBOTURA INC. β ALL RIGHTS RESERVED
RevCon 3 Performance Baseline | Authorized Strategic Integrator (ASI) Integration Model | Class 2 OER Β±15%
RevCon 3 Performance Baseline | Authorized Strategic Integrator (ASI) Integration Model | Class 2 OER Β±15%