Pregenesis Protocol — Technical Design Specification
Modules 0A, 0B & 0C
Truck Intake & Scale Airlock, Feedstock Ingest & Trough System, Exit Airlock Scale Building
Complete feedstock reception system — TISAB, Feedstock Ingest, dual troughs, EASB
Document Control
| Document Number | CBT-PRE-TDS-002 |
| Revision | Rev 1 — 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 baseline factory |
| Chairman | Allen Witters |
Revision History
| Rev | Date | Author | Description |
|---|---|---|---|
| 0 | April 2026 | Carbotura Engineering | Initial Issue — Class 4 Preliminary (±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 — Material Flow Overview
Process Flow
Module 0A · TISAB
Truck Arrival
RFID + Manifest
RFID + Manifest
↓
NTEP Weighbridge
Gross Weight ±20 lb
Gross Weight ±20 lb
↓
Airlock Hold
15 sec · −0.02 in. WC
15 sec · −0.02 in. WC
→
Module 0B · Feedstock Ingest
Bay Assignment
LED Signage
LED Signage
↓
Hydraulic Bridge
45–70° Raise
45–70° Raise
↓
Trough 1
MSW + Tires
MSW + Tires
↓
Trough 2
Sludge + Ash
Sludge + Ash
→
Shredder Train · Modules 1–4
Tire Pre-Shredder
↓
Primary Shredder
SHRD-SHR-001/002 · 380 kW
SHRD-SHR-001/002 · 380 kW
↓
MFS Stage 1
Bulk Ferrous → FCB-001/002
Bulk Ferrous → FCB-001/002
↓
Hammermill
P80 ≤25 mm
P80 ≤25 mm
↓
MFS Stage 2
Fine Wire → FCB-003/004
Fine Wire → FCB-003/004
↓
Rotational Mixer
EAF = 0.25 · CV <5%
EAF = 0.25 · CV <5%
↓
Regenesis Feed Bin
→
Output
To Regenesis MCR
Blended · EAF 0.25 confirmed
Blended · EAF 0.25 confirmed
T2 Processing · Ash Path
NIR Moisture Sensor
Routing decision
Routing decision
↓
Lumpbreaker
↓
VRM Pulverizer
P80 <500 µm · ATEX Z21
P80 <500 µm · ATEX Z21
↓
Ash Silo
ASL-001/002
ASL-001/002
↑ feeds Rotational Mixer
Also: Module 0C · EASB — Tare weight confirmation ±5% · 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 — 8-State Door Interlock Machine
State Machine
[*] Power Up
Raise request + interlocks clear
S0 — Both Doors Closed
Standby
Standby
Raise request + interlocks clear
S1 — Entry Door Opening
Entry door fully open
S2 — Truck Entering · On Scale
Truck on scale confirmed
S3 — Entry Door Closing
Entry door sealed
S4 — AIRLOCK HOLD
−0.02 to −0.05 in. WC · NTEP weight captured · Load acceptance confirmed
−0.02 to −0.05 in. WC · NTEP weight captured · Load acceptance confirmed
Weight captured + acceptance confirmed
S5 — Exit Door Opening
Exit door fully open
S6 — Truck Exiting Floor
Truck clear + dump body down
S7 — Exit Door Closing · Lane Reset
Exit door sealed → return to S0
↩
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 — Module 0A), feedstock receiving on the Feedstock Ingest (Module 0B) with dual-trough material routing, and truck exit through the Exit Airlock Scale Building (EASB — 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 (–0.05 to –0.10 in. WC throughout the Feedstock Ingest; –0.02 to –0.05 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 Feedstock Ingest (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 — 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 1–6 size reduction, ferrous separation, blending | CBT-PRE-TDS-003 |
| Excluded: T2 Processing | Trough 2 thermal drying and pulverizing to <500 µm | 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 — 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 | ~985–995 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 | ~0.5–1.5% 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 — 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 Feedstock Ingest, and exit via the EASB mirror airlock. The TISAB/EASB airlock system maintains the facility negative pressure boundary at all times — 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 Feedstock Ingest contains two parallel troughs running lengthwise. Trough 1 receives Manufacturing Feedstock (MSW and tires); hydraulic drawbridges raise to allow rear discharge 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 — RFID tag read at lane entry | EPC tag capture |
| 2 | TISAB | Airlock hold — pressure equalization | –0.02 to –0.05 in. WC vs. outside |
| 3 | TISAB | Weighbridge measures gross weight | ±20 lb legal-for-trade (NTEP) |
| 4 | TISAB | Exit door opens, truck enters Feedstock Ingest | SCADA bay assignment signal |
| 5 | Feedstock Ingest | Bay assignment via LED signage — Trough 1 or 2 | Load manifest match confirmed |
| 6 | Feedstock Ingest | Hydraulic bridge raises | <60 sec raise cycle |
| 8 | Feedstock Ingest | Truck tips Manufacturing Feedstock into trough | Gravity discharge; all material confined to trough |
| 8 | Feedstock Ingest | Bridge lowers; truck proceeds to EASB | <60 sec lower cycle |
| 9 | EASB | Airlock hold — pressure equalization | –0.02 to –0.05 in. WC vs. outside |
| 10 | EASB | Tare weight confirmed | ±20 lb legal-for-trade |
| 11 | EASB | Payload reconciliation (gross – tare = net) | ±5% reconciliation tolerance |
| 12 | EASB | Truck exits — 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 60–85% sludge; 5–30% ash |
| Output to Shredder Train | Trough 1 lift conveyor | ~985–995 | After magnetic head pulley ferrous removal (~0.5–1.5%) |
| 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 | ~5–15 | Estimated 0.5–1.5% 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 | –0.05 to –0.10 in. WC | Relative to TISAB/EASB interior |
| TISAB/EASB pressure | –0.02 to –0.05 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 | 0–12 ft/min variable | SCADA-controlled via proportional hydraulic valve |
| Payload reconciliation tolerance | ±5% | TISAB gross vs EASB tare; pass/fail threshold |
| Truck throughput (design) | 60+ trucks/hour per direction | 2 lanes × 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 — MSW & Tire Feedstock Design Envelope
| Component | P50 Range (wt%) | P90 Design Max (wt%) | Design Consideration |
|---|---|---|---|
| Paper / Cardboard | 20–28% | 35% | High cellulose; manageable via walking floor |
| Plastics (mixed) | 12–18% | 22% | Mixed polymers; no special handling required |
| Food organics | 20–35% | 42% | High moisture; contained by negative pressure + APS |
| Yard trimmings | 5–15% | 20% | Seasonal variation; lignocellulosic bulk |
| Ferrous metals | 3–6% | 8% | Recovered at magnetic head pulley on lift conveyor |
| Non-ferrous metals | 1–3% | 4% | Pass-through to Shredder Train |
| Glass / ceramics | 3–6% | 8% | Inert; manageable with AR400-lined trough |
| Textiles / Rubber | 2–6% | 10% | Rope/textiles can bridge — walking floor handles |
| Whole tires | 0–10% | 40% | Bridge-tip directly; tires 100% by day acceptable |
| Li-ion batteries | Trace | ANY DETECTION | Quarantine protocol — 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 — load rejected before rear discharge |
| 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 | Biohazard | Manifest review | Reject — not accepted as Manufacturing Feedstock |
5. Module Equipment Specifications
Equipment Visual Reference
Image Management
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5.1 TISAB — Truck Intake & Scale Airlock Building TISB-BLD-001/002
TISAB — Truck Intake & Scale Airlock Building TISB-BLD-001/002
Building Type
Rigid steel frame with insulated metal panel — pressure-differential sealed, heavy door framing
Configuration
2 parallel drive-through lanes, fully enclosed
Lane Dimensions
20 ft wide × 110 ft long per lane
Total TISAB Footprint
~50 ft × 100 ft (including wall thickness and service access)
Ceiling Height (clear)
24 ft minimum — accommodates loaded semi-trailer clearance with body-up detection clearance
Doors Per Lane
2× automatic high-speed insulated roll-up doors (4 doors total)
Door Dimensions
20 ft W × 16 ft H clear opening per door — high-speed insulated sectional overhead, R-20, ATEX Zone 2, ≥0.05 in. WC pressure-differential rated
Door Cycle Rating
Minimum 50,000 cycles/year
Door Interlock
Entry door must fully close and seal before exit door opens — true airlock sequence
Weighbridge Type
In-ground certified legal-for-trade weighbridge, pit-mount, per NIST Handbook 44
Weighbridge Capacity
105,000 lb NTEP certified — legal-for-trade
Weighbridge Accuracy
±20 lb
Weighbridge Platform
85 ft L × 13 ft W per lane — full semi-trailer wheelbase
Body-Up Detection
MANDATORY — TISAB-HID-001 through -004: Infrared through-beam sensor, 14 ft AFF, 20 ft span, full door width. Trip condition: any vehicle component >14 ft AFF → ALARM: DUMP BODY ELEVATED. Door remains closed; non-overridable without supervisor credential.
RFID/Transponder
Passive UHF RFID readers at lane entry — industrial weatherproof grade
Airlock Cycle Time
<3 minutes per truck (door close + verification + door open)
Pressure Differential
–0.02 to –0.05 in. WC relative to outside atmosphere
APS Capture (Normal)
400 CFM — process-capture basis; no dilution air
APS Capture (Peak)
700 CFM — during peak truck traffic and door cycling
Estimated CAPEX
$1.8M–$2.8M per building [Class 2 ±15%, 2026 USD] — includes rigid frame structure, sectional doors, weighbridges, body-up detection, RFID, fire suppression
5.2 Trough 1 — MSW & Tires DUMP-TR1-001
Trough 1 — 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 × 200 ft long × 16 ft deep (clear inside)
Surge Buffer (design)
4-hour supply at 1,000 TPD = ~167 tons at 425 lb/yd³ 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 — each rated 1,000 TPD full throughput
Walking Floor Speed
0–12 ft/min variable, SCADA-controlled via proportional hydraulic valve
Lift Conveyor Type
2× 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
18–22 degrees
Magnetic Head Pulley
Rare-earth permanent magnet; continuous ferrous removal at conveyor discharge; est. 0.5–1.5% of stream
5.2.1 Feedstock Ingest Station Layout — 5-Station Design
Station Assignment — Locked Design (ECN-002, ECN-003)
The Feedstock Ingest is designed around five discharge stations. Stations 1–4 are trough tipping bays served by hydraulic counterweighted drawbridges. Station 5 is the Module 0D Liquid Biosludge Delivery Station — no drawbridge, no trough access. All station assignments are SCADA-controlled via vehicle type manifest flag at TISAB entry.
| Station | Tag | Trough / Zone | Vehicle Type | Manifest Flag | Discharge Method | Bridge |
|---|---|---|---|---|---|---|
| Station 1 | DUMP-BAY-001A | Trough 1 — Lane A | Semi end-dump / walking floor, dump truck | SEMI-ENDDUMP · SEMI-WALKFLOOR · DUMP-TRUCK | Rear gravity discharge or walking floor ejection into trough | RAISES (end-dump) / DOWN (walking floor) |
| Station 2 | DUMP-BAY-001B | Trough 1 — Lane B | Semi end-dump / walking floor, compression truck | SEMI-ENDDUMP · COMPRESSION | Rear gravity discharge, walking floor ejection, or horizontal packing blade ejection via head-end opening | RAISES (end-dump) / DOWN (compression/walkfloor) |
| Station 3 | DUMP-BAY-002A | Trough 2 — Lane A | Semi end-dump / walking floor, dump truck | SEMI-ENDDUMP · SEMI-WALKFLOOR · DUMP-TRUCK | Rear gravity discharge or walking floor ejection — ash and sludge feedstock only | RAISES (end-dump) / DOWN (walking floor) |
| Station 4 | DUMP-BAY-002B | Trough 2 — Lane B | Semi end-dump / walking floor, compression truck | SEMI-ENDDUMP · COMPRESSION | Rear gravity discharge, walking floor ejection, or horizontal packing blade ejection via head-end opening — ash and sludge feedstock only | RAISES (end-dump) / DOWN (compression/walkfloor) |
| Station 5 | LBS-MNF-001 | Module 0D — Lane D | Liquid biosludge tanker | TANKER-LIQUID | Gravity drain or pump via 4-in. tri-clamp manifold — no trough, no drawbridge | N/A — no bridge |
Roll-off Trucks (ROLLOFF manifest)
Roll-off trucks are assigned to the head-end opening bay of the appropriate trough (Station 1 or 3 depending on material type). Container tilts at floor grade — same as compression truck head-end discharge geometry. Bridge stays DOWN.
5.3 Hydraulic Drawbridge System DUMP-HDB-xxx
Counterweighted Drive-Over Drawbridge System — Both Troughs DUMP-HDB-001/002/003/004
Design Concept
Trucks drive forward onto the drawbridge, which spans the full trough width. The bridge is the structural roadway over the trough. Truck stops, auto-chocks engage, then the entire bridge span hinges upward from the entrance-side pivot — exposing the trough below and allowing the truck dump body to raise rearward and discharge Manufacturing Feedstock into the trough. Drive-through operation — no reversing required.
Configuration
2 drawbridges per lane · 2 lanes · 4 drawbridges total. Troughs parallel at 24-ft centers. Each bridge independently operated.
Bridge Span
16 ft (4.88 m) clear span across trough. Bridge is the truck roadway; trucks drive onto and stop over the trough.
Hinge Location
Entrance side — pivot at the end from which the truck entered. Full span raises from this fixed pivot point. Exit/dump end rises to operating angle.
Operating Angle
45° nominal raise angle. Full span raises as a single rigid unit. Provides clearance for truck dump body to elevate rearward and discharge into trough below.
Counterweight
Factory-fitted counterweight balances full span + maximum truck load at hinge. Minimal hydraulic energy required for raise/lower cycle. HPU sized for counterbalanced load only.
Load Rating
80,000 lb GVW minimum; 100,000 lb design load — AASHTO HL-93 + 25% dynamic impact factor. Rated for fully loaded tandem-axle transfer trailer.
Structural Frame
W-section steel beams, hot-dip galvanized; AR400 wear surface deck; lateral wheel guides both sides prevent truck drift during approach and positioning.
Auto-Chock System
Automatic wheel chocks engage on truck-stop confirmation. Chock engagement confirmed via sensor before bridge raise is permitted. Chocks hold truck stationary during full raise/lower cycle and dump body operation. Chock release only permitted after bridge fully lowered and latched.
Rising Trough Curb — DUMP-RCB-001/002/003/004
Mechanical rising curb — mandatory rollback prevention. A steel curb plate, 10 in. (254 mm) above finished slab, rises automatically on bridge raise command — interlocked in series with the bridge raise interlock chain. Curb MUST confirm raised position (DUMP-RCB-POS-001 sensor) before bridge raise is permitted. Curb blocks any truck or load from rolling back into the open trough during or after discharge. Curb lowers only after bridge is fully DOWN and latched. Actuator: hydraulic or electromechanical; AR400 face plate; rated for 105,000 lb vehicle impact. Tag: DUMP-RCB-001 (Trough 1A), -002 (Trough 1B), -003 (Trough 2A), -004 (Trough 2B).
Raise/Lower Cycle
<60 seconds full travel (0° to 45° and return). Hydraulic actuators sized for counterbalanced load; smooth acceleration/deceleration profile to prevent load shift.
Trough Interlock
Adjacent bridge on same trough — hard interlock prevents simultaneous raise. Both bridges on opposite troughs may operate simultaneously (independent HPUs, independent interlocks).
Safety — Personnel
Laser curtain / photo-eye array confirms no personnel in trough zone beneath bridge before raise permitted — Class IV per ANSI/NFPA 79.
Safety — APS
APS extraction rate increases automatically on bridge raise signal. Trough zone maintained under negative pressure during full open dump cycle. Bridge may not remain raised >15 min without confirmed APS capture.
Emergency Stop
E-stop pull cords on both sides of each bridge at grade level; mushroom-head E-stop at each HPU station; SCADA alarm logged with timestamp on any E-stop activation.
CAPEX (per trough pair)
$600K–$1.2M per trough (2 bridges) — custom fabrication with counterweight system; performance-specified per this TDS [Class 2 ±15%].
5.4 Fire Suppression System — PIMB Trough Zone
Fire Suppression — Governing Standards
NFPA 13 (Sprinkler Systems) · NFPA 15 (Water Spray Fixed Systems) · NFPA 72 (Fire Alarm) · NFPA 652 (Combustible Dust) · NFPA 855 (Energy Storage — Li-battery). All systems automatic — no manual activation required for initial suppression response.
| Zone | System | Activation | Standard | Notes |
|---|---|---|---|---|
| Trough 1 & 2 — primary | Thermal-camera-directed oscillating monitor nozzles (DUMP-FPS-MON-001 through -008) | Thermal camera (DUMP-TIC-001 through -008) detects event above threshold → SCADA directs nearest monitor nozzle to train on heat source; nozzle oscillates across hot zone until temperature drops | NFPA 15 — Water Spray Fixed Systems | 2 monitor nozzles per trough bay; oscillating traverse covers full trough length. Cameras double as Li-battery detection cameras. |
| Trough zone — backup | Wet pipe sprinkler system — NFPA 13 industrial spacing overhead | Automatic — fusible link or glass bulb; no manual intervention required | NFPA 13 | Provides coverage if monitor nozzle alone insufficient. Water agent confirmed effective for MSW deep-seated fires and Li-battery thermal runaway per NFPA 855. |
| Enclosed conveyors — SHRD-CV-001–007 | Nitrogen inerting system (NIT-CV-001) | CO detector or thermal sensor within conveyor enclosure → automatic N₂ flood | NFPA 69 — Explosion Prevention | Oxygen exclusion effective in enclosed conveyor geometry. Personnel excluded during operation — no asphyxiation risk. |
| VRM enclosure — SHRD-APZ-001/002 | Nitrogen inerting system (NIT-APZ-001) | Mill temperature or CO sensor → automatic N₂ flood | NFPA 69 | Mill fires in enclosed grinding chambers respond to nitrogen inerting. LOTO required before any access after N₂ activation. |
| MCC / Electrical rooms | Clean agent suppression (FM-200 or Novec 1230) | Smoke/heat detector → automatic clean agent discharge | NFPA 2001 | No water in electrical rooms. CO₂ not used — occupied space risk. |
| PIMB general | Wet pipe sprinkler — NFPA 13 ordinary hazard | Automatic fusible link | NFPA 13 | General building coverage excluding trough bays (which have dedicated systems above). |
| Parameter | Value |
|---|---|
| Monitor nozzle OEM | Elkhart Brass / Task Force Tips — oscillating industrial monitor; SCADA-controlled traverse |
| Monitor nozzle flow rate | 500–2,000 GPM per nozzle (adjustable via SCADA); sized per NFPA 15 hydraulic calculation |
| Thermal camera trigger threshold | OPEN — OER Gate 2: set point to be defined based on feedstock thermal profile and NFPA 652 DHA (EDP-IRL-02 dependency) |
| Water supply | Dedicated fire water storage tank + fire pump — minimum 60-minute duration at design flow rate; sized per NFPA 13/15 hydraulic calculation |
| N₂ supply | Bulk liquid nitrogen storage — bulk tank sized for 3 full flood volumes; automatic vaporizer |
| SCADA integration | All fire detection events logged; APS automatically ramps to maximum on fire alarm signal; bridge raise blocked during active suppression event |
| CAPEX (fire suppression — all systems) | $450K–$900K [Class 2 ±15%, 2026 USD] — includes monitor nozzles, wet pipe, N₂ inerting, clean agent, fire pump, detection |
6. APS Interface Register
6.1 APS Capture Ports — Feedstock Ingest Zone
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 (°C) | Material | Recovery Value |
|---|---|---|---|---|---|---|
| TISAB (0A) | Ceiling duct — building | 400 | 700 | Ambient | Coarse particulate, minor biogas | Carbon fines to recovery |
| Trough 1 (0B) | Open-top duct pickup | 600 | 1,000 | Ambient–35 | MSW particulate, biogas traces, rubber dust | Carbon fines; biogas to APS recovery |
| Trough 2 (0B) | Open-top duct pickup | 500 | 900 | Ambient–45 | Sludge vapors, ash particulate, H₂S | Condensate to water treatment; dry fines to recovery |
| Feedstock Ingest general | Building envelope ceiling plenum | 300 | 500 | Ambient | General building air, minor fugitive particulate | General containment |
| EASB (0C) | Ceiling duct — building | 400 | 700 | Ambient | Coarse particulate, minor biogas from empty trucks | Carbon fines to recovery |
| Head-end opening hoods — DUMP-APS-HE-001 (Trough 1) | Dedicated head-end capture hood | 1,200 | 2,000 | Ambient–35 | MSW ejection particulate, rubber dust | Carbon fines recovery stream |
| Head-end opening hoods — DUMP-APS-HE-002 (Trough 2) | Dedicated head-end capture hood | 1,200 | 2,000 | Ambient–35 | Ash and sludge particulate during head-end discharge | Carbon fines recovery stream |
| Module 0D — LBS-VNT-001 (Liquid Biosludge Station) | Dedicated vapor capture hood at manifold | 800 | 1,400 | Ambient | H₂S, NH₃, methane from liquid transfer | APS odor control / treatment stream |
| TOTAL — All PIMB Modules (0A/0B/0C + 0D + Head-End) | All capture points combined | ~5,100 | ~8,700 | — | — | — |
7. Modular Installability & Interface Control
7.1 Skid Interface Specifications
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 ASI (Authorized Strategic Integrator) Standardized Connectors per CBT-PRE-ICD-001 Rev 1.
ICD Rev 1 — 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 3–4 (Rev 0) to IRL 5 (Rev 1). See the full ICD document: CBT-PRE-ICD-001 Rev 1 →| Interface | ICD Reference | Connection Type | Status |
|---|---|---|---|
| TISAB entry → Feedstock Ingest | ICD-TISB-DUMP-001 | Pressure boundary door + APS duct + Modbus TCP data | DEFINED — Rev 1 |
| Feedstock Ingest → EASB | ICD-DUMP-EASB-001 | Pressure boundary door + APS duct + Modbus TCP data | DEFINED — Rev 1 |
| Trough 1 lift conveyor → Shredder Train | ICD-DUMP-SHRD-001 | Flanged AR400 chute + E-stop SIL 1 + Modbus TCP feed rate | DEFINED — Rev 1 |
| Trough 2 feed conveyor → T2 Processing | ICD-DUMP-T2PR-001 | Flanged 316L SS chute + NIR analog + Modbus TCP routing | DEFINED — Rev 1 |
| All modules → APS | ICD-DUMP-APS-001 | 5× ASI-APS-FLG-6IN-RD + Rosemount 3051 DP + Modbus TCP | DEFINED — Rev 1 |
| TISAB/EASB → SCADA Master | ICD-TISB-SCADA-001 | Full Modbus TCP/IP I/O marshaling — weighbridge, RFID, doors, bay LED | DEFINED — 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
AC Utility Bus — Frequency Specification
Field-Switchable Inverter — 50Hz / 60Hz
The AC utility bus inverter is field-switchable at commissioning. USA deployments: 60Hz — NEMA 5-15/5-20 convenience outlets, 120V single-phase plug power for tools, computers, and site equipment. All international deployments: 50Hz — IEC standard for Europe, Asia, Africa, Australia, and Middle East markets. Frequency is set via firmware parameter or DIP switch at commissioning; no hardware change required. All large motor loads are VFD-driven and frequency-agnostic — this setting governs plug power and utility distribution only.
| Deployment Region | AC Bus Frequency | Plug Standard | Voltage | Set At |
|---|---|---|---|---|
| USA | 60Hz | NEMA 5-15 / 5-20 | 120V single-phase / 208V 3-phase | Commissioning — firmware parameter |
| Europe / UK | 50Hz | CEE 7/4 (Schuko) / BS 1363 | 230V single-phase / 400V 3-phase | Commissioning — firmware parameter |
| Asia / Pacific | 50Hz | IEC 60083 regional variants | 220–240V single-phase | Commissioning — firmware parameter |
| Middle East / Africa | 50Hz | BS 546 / regional variants | 220–240V single-phase | Commissioning — firmware parameter |
| All large motors (VFD-driven) | Frequency-agnostic | N/A — direct HVDC or VFD output | Per VFD output spec | No setting required |
| 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 |
| Feedstock Ingest (0B) | Walking floors (2× T1 + 2× T2) | 120 | 240 | Walking floor HPU drives scale with throughput |
| Feedstock Ingest (0B) | Lift conveyors (2× Trough 1) | 80 | 160 | 2× 75 HP VFD motors at 50% duty |
| Feedstock Ingest (0B) | Bridge HPUs (4 sets) | 40 | 80 | Intermittent; 50 HP each during bridge cycle |
| Feedstock Ingest (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 — 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 |
|---|---|---|---|---|
| Robertson Building Systems / Nucor Building Systems | USA / Canada | 25 yr structural, 20 yr panel | Rigid steel frame; insulated metal panel; heavy industrial door framing; pressure-differential capable | Pre-engineered rigid frame — suitable for ATEX/negative pressure industrial facilities |
| ASSA ABLOY / Hörmann | USA / Germany | 5 yr mechanism, 2 yr seal | High-speed insulated sectional overhead doors; R-20 minimum; ATEX Zone 2 rated; ≥0.05 in. WC differential | Door OEM — supplied as sub-contract to building integrator |
| ClearSpan Fabric Structures | USA | Yes — 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 — 24 months parts + labor | Legal-for-trade, NTEP certified, pit-mount, SCADA integration | Global standard; full service network |
| Rice Lake Weighing Systems | USA | Yes — 24 months | Full range pit-mount legal-for-trade; SCADA integration | Strong USA dealer network; competitive pricing |
| Avery Weigh-Tronix | USA / UK | Yes — 24 months | OIML/NTEP dual-certified, pit-mount, SCADA/ERP ready | Global network; strong in regulated industrial applications |
10. CAPEX Estimate
10.1 Module CAPEX Summary — Class 2 ±15%
AACE Classification — Class 2 (±15%) | 2026 USD
This capital cost estimate is classified as Class 2 (±15%) OEM Engineering Release per AACE International RP 18R-97. All values in 2026 USD. Estimating methodology: factored/parametric — equipment costs from budget quotes, ROM quotes, and industry benchmarks.| Line Item | Low Estimate | High Estimate | Basis |
|---|---|---|---|
| TISAB building (Rigid steel frame + insulated metal panel + fitout) | $1.8M | $2.8M | Rigid frame structure; 20 ft lanes × 110 ft; sectional overhead doors; 105,000 lb NTEP weighbridges; body-up detection; RFID [Class 2 ±15%] |
| TISAB scales + weighbridge systems (2 lanes) | $120K | $250K | 2× NTEP-certified pit-mount scales + controllers |
| TISAB doors + controls + RFID | $80K | $150K | 4 doors, PLC interlocks, RFID readers, safety systems |
| Feedstock Ingest 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 (2×) + lift conveyors (2×) + 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 (2×, 316L) + feed conveyors (2×) | $550K | $1.1M | 316L SS slats + corrosion premium; screw/en-masse conveyors |
| EASB building (Rigid steel frame — mirror of TISAB) | $1.8M | $2.8M | Same specification as TISAB Rev 1; rigid frame, sectional doors, weighbridge, RFID, body-up detection [Class 2 ±15%] |
| Thermal cameras + Li-battery detection | $80K | $150K | Fixed thermal cameras at TISAB approach; SCADA integration |
| Subtotal — Direct Equipment | $5.73M | $11.35M | Lines above |
| Electrical, instrumentation, controls (15%) | $860K | $1.7M | E&I at 15% of equipment subtotal — 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 — Modules 0A/0B/0C | $8.57M | $16.96M | Class 2 ±15% | AACE 18R-97 | 2026 USD |
11. Testing and Acceptance Criteria
11.1 Factory Acceptance Test (FAT)
Section Status — In Development
FAT/SAT acceptance criteria for Modules 0A/0B/0C to be developed by ASI in conjunction with Carbotura Engineering. Minimum required: functional interlock verification, weighbridge calibration verification, APS negative pressure confirmation, and bridge raise/lower cycle timing test.
| Test | Acceptance Criterion | Method | Status |
|---|---|---|---|
| Weighbridge accuracy | ±20 lb at 80,000 lb GVW | NTEP certified test weights | PENDING |
| Airlock door interlock cycle | Full state machine S0→S7→S0 with no faults | Automated SCADA test sequence | PENDING |
| Bridge raise/lower cycle time | <60 seconds full travel | Stop watch + encoder log | PENDING |
| Auto-chock engagement | Both sensors confirm <5 seconds | Test truck simulation | PENDING |
| APS negative pressure | −0.05 in. WC minimum in trough zone | Calibrated Magnehelic gauge | PENDING |
| E-stop function | All motion halts <2 seconds on activation | Manual E-stop activation test | PENDING |
11.2 Site Acceptance Test (SAT)
SAT protocol to be defined by Carbotura Engineering following ASI FAT completion. SAT scope covers: full truck cycle under live operations, weighbridge correlation with truck manifest, negative pressure verification under operational load, SCADA data historian validation, and 72-hour continuous run at design throughput. SAT sign-off required before commercial operations commencing.
12. Interface Control Summary
12.1 ICD Cross-Reference — Module 0A/0B/0C
Cross-Reference
Detailed interface specifications are governed by CBT-PRE-ICD-001 Rev 1. This section provides a summary cross-reference only. Any conflict between this TDS and the ICD shall be resolved in favor of the ICD.
| Interface | ICD Section | Counterpart Module | Status |
|---|---|---|---|
| Trough 1 lift conveyor discharge → Shredder Train | ICD §3.1 | Module 1 — Primary Shredder | DEFINED |
| Trough 2 walking floor → T2 Processing | ICD §3.2 | Module T2 | DEFINED |
| APS common manifold tie-in | ICD §4.1 | APS Module | PENDING |
| Recyclotron Feed Header (RFH) header | ICD §5.1 | Regenesis MCR | PENDING |
| SCADA tag handoff — TISAB/EASB to Feedstock Ingest | ICD §6.3 | SCADA / DCS | DEFINED |
| 32 MW PowerBlock electrical tie-in | ICD §7.2 | PowerBlock Module | PENDING |
13. TRL / ERL / IRL Assessment
DOE Cooperative Agreement — Industrial Feedstock MCR Mode
Carbotura has applied for two DOE Cooperative Agreement grants covering use of Coal Mine Tailings, Coal Energy Plant Ash, WTE Ash, and Critical Materials and Minerals (CMM) as primary feedstocks — up to 100% by mass — with MSW blended at variable ratios for Island Mode energy self-sufficiency. This program utilizes the identical Pregenesis and Regenesis equipment with different feed rates and operating recipes (Industrial Feedstock MCR Mode). Commercial proof-of-concept and DOE co-funding will advance the system TRL from 8 toward 9 across all feedstock categories. Enhancement Admix equipment (SHRD-EAS, SHRD-APZ, SHRD-LWF) is primary equipment in Industrial Feedstock MCR Mode.
13.1 Technology and Engineering Readiness
| Equipment / System | TRL | ERL | IRL | Assessment Notes |
|---|---|---|---|---|
| Rigid steel frame + insulated metal panel buildings (TISAB/EASB) | 9 | 5 | 5 | Fully commercial; pre-engineered rigid frame widely deployed for negative-pressure industrial facilities |
| 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) |
| Counterweighted drive-over drawbridge | 8 | 4 | 4 | Custom adaptation of proven hydraulic bridge technology; performance-spec procurement; limited rear discharge 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 | 8 | 4 | 5 | Direct commercial analog: enclosed vehicle airlock with negative pressure management is proven at TRL 9 in hundreds of WTE enclosed receiving halls globally (Covanta, Suez, Veolia). All components (roll-up doors, weighbridge, SCADA, APS) are TRL 9. APS product capture vs. combustion air induction is an incremental refinement on proven architecture. Not yet commissioned in ACM context → TRL 8 not 9. |
| 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 0→Rev 1 with full ICD definition |
14. Confidence Factor
| Factor | Weight | Score (0–10) | Weighted Score | Rationale |
|---|---|---|---|---|
| Technology maturity (TRL) | 25% | 9.0 | 2.13 | Most equipment TRL 9; hydraulic bridges TRL 7–8; integrated airlock TRL 6–7 |
| Engineering completeness (ERL) | 20% | 8.0 | 1.60 | ERL 4–5 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% | — | 8.24 / 10 = 82.4% | GOOD — Investor-bankable at Rev 1 Class 2 OER |
15. Availability Model
15.1 Equipment Availability and Redundancy
| Equipment | MA | MTBF (hr) | MTTR (hr) | Notes |
|---|---|---|---|---|
| TISAB/EASB roll-up doors | >98% | >5,000 | 1–2 | 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 | 92–95% | 1,000–2,000 | 2–4 | Custom hydraulic system; cylinder seal wear primary failure mode; critical path for system OA (calculated — industry hydraulic cylinder benchmark) |
| Walking floor systems | 94–97% | 2,000–4,000 | 2–4 | 50% duty cycle on 2× units; slat replacement is planned maintenance (Keith Manufacturing reference data) |
| Lift conveyors (Trough 1) | 96–99% | 3,000–6,000 | 1–3 | 50% duty cycle; belt and magnetic head pulley are planned maintenance items |
| Feed conveyors (Trough 2) | 95–98% | 2,500–5,000 | 1–3 | 316L SS screw conveyor; bearing and seal service in corrosive sludge environment |
| System OA — 0A/0B/0C | ~93% | — | — | Dominated by hydraulic bridge MA; N+1 walking floor/conveyor provides headroom. P50 throughput: 930 TPD avg. |
16. Risk Register
16.1 Module Risk Register
R-01 — Hydraulic bridge custom fabrication — schedule risk
Severity: MEDIUM · S/P/D/RPN: OPEN — Designer to populate at Rev N+1Mitigation: Critical path at 20–32 weeks. Early procurement decision. ICD finalization before fabrication release. Dual-source HPU components.
R-02 — Trough 2 sludge leachate — near-zero discharge compliance
Severity: MEDIUM · S/P/D/RPN: OPEN — Designer to populate at Rev N+1Mitigation: 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 — fire risk at rear discharge or in trough
Severity: HIGH · S/P/D/RPN: OPEN — Designer to populate at Rev N+1Mitigation: Thermal cameras at TISAB approach for truck load screening. Quarantine bay QA-01 with water deluge for pre-discharge events. Post-discharge: thermal-camera-directed oscillating monitor nozzles (NFPA 15) + wet pipe sprinkler backup (NFPA 13) activate automatically. Li-battery protocol: continuous water application required — see §5.4 Fire Suppression and OPS-002 §13B.
R-04 — Payload reconciliation discrepancy (>5%) — operational data quality
Severity: LOW · S/P/D/RPN: OPEN — Designer to populate at Rev N+1Mitigation: 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
Severity: MEDIUM · S/P/D/RPN: OPEN — Designer to populate at Rev N+1Mitigation: 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
Severity: MEDIUM · S/P/D/RPN: OPEN — Designer to populate at Rev N+1Mitigation: 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)
Severity: MEDIUM · S/P/D/RPN: OPEN — Designer to populate at Rev N+1Mitigation: Redundant door interlocks. Pressure monitoring with SCADA alarm at –0.01 in. WC threshold. Automatic APS fan speed increase on pressure drop.
17. Document Control
17.1 Revision History
| Rev | Date | Author | Description | Approved By |
|---|---|---|---|---|
| Rev 0 | March 2026 | Carbotura Engineering | Initial issue — Class 4 Preliminary | A. Witters |
| Rev 1 | April 2026 | Carbotura Engineering | Upgrade to Class 2 OER — drawbridge mechanism corrected; Feedstock Ingest terminology; ASI (Authorized Strategic Integrator) designation; counterweight HPU; auto-chock specification | A. Witters |
17.2 Review and Approval Status
| Role | Name | Status | Date |
|---|---|---|---|
| Author — Lead Systems Architect | Carbotura Engineering | ISSUED | April 2026 |
| Structural PE Review | TBD — pending PE engagement | PENDING | — |
| Mechanical PE Review | TBD — pending PE engagement | PENDING | — |
| ASI Review — ASI (Authorized Strategic Integrator) | TBD | PENDING | — |
| Owner Approval | A. Witters — Chairman | PENDING | — |
18. Warranty Register
18.1 OEM Warranty Terms — Module 0A/0B/0C
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 |
|---|---|---|---|---|
| TISAB/EASB buildings (Rigid steel frame + insulated panel) | Robertson / Nucor (building) + ASSA ABLOY / Hörmann (doors) | 25 yr structural frame, 20 yr panel, 5 yr door mechanism | Structural frame and insulated metal panel envelope | Door warranty is separate sub-contract with door OEM; ASI manages overall warranty pass-through |
| 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 — 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 — 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 — CBT-PRE-TDS-002 | Rev 1 | 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%