Pregenesis Protocol — Technical Design Specification
Modules 1–4: Primary Shredding, Hammermill,
Ash Pulverizer & Rotational Mixer
Pregenesis Shredder Train — complete size reduction, ferrous separation, AFR-controlled blending, and Regenesis feed metering
Document Control
| Document Number | CBT-PRE-TDS-003 |
| 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 | Issued for Review — PE Sign-Off / Investor Bill of Sale |
| Owner | Carbotura Inc. — Engineering |
| Quality Standard | ISO 9001:2015 |
| Authorized Strategic Integrator (ASI) | Role open to qualified ASI candidates per CBT-ASI-QUAL-001 |
| 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%). ICD table absent from Section 9. |
| 1 | April 2026 | Lead Systems Architect / OEM Engineering Director | Class 2 OER Upgrade. Full ICD register established per CBT-PRE-ICD-001 Rev 1 (7 ICDs, all DEFINED). Skid-Integrated Spring Isolation specification added for SHRD-SHR-001/002 and SHRD-HMR-001/002. ASI terminology applied throughout. Terminology Firewall v1.0 enforced. RevCon 3 baseline confirmed. |
Table of Contents
- Executive Summary
- Facility Context & Module Boundaries
- Process Description
- Feedstock Design Envelope
- Canonical AFR Definition
- Module Equipment Specifications
- APS Interface Register
- Ash Supply & Logistics Basis
- Modular Installability & Interface Control (ICD Table)
- Utilities Register & Energy Balance
- Vendor Matrix
- CAPEX Estimate
- TRL / ERL / IRL Assessment
- Confidence Factor
- Availability Model
- Dust Hazard Analysis & Area Classification
- Risk Register
- Warranty Register
1. Executive Summary
DIAG-SHRD-001
Shredder Train — Process Flow & Equipment Sequence
Process Flow
Feed Input
Trough 1
Lift Conveyor Discharge
Lift Conveyor Discharge
→
Size Reduction
Tire Pre-Shredder
SHRD-TPS-001/002
SHRD-TPS-001/002
↓
Primary Shredder
SHRD-SHR-001/002 · 380 kW · Spring ISO
SHRD-SHR-001/002 · 380 kW · Spring ISO
↓
MFS Stage 1
Bulk Ferrous → FCB-001/002 · −18 TPD
Bulk Ferrous → FCB-001/002 · −18 TPD
↓
Hammermill
SHRD-HMR-001/002 · P80 ≤25 mm · Spring ISO
SHRD-HMR-001/002 · P80 ≤25 mm · Spring ISO
↓
MFS Stage 2
Fine Wire → FCB-003/004 · −7 TPD
Fine Wire → FCB-003/004 · −7 TPD
→
Susceptor Preparation
Ash Silos ASL-001/002
Stream A WTE · Stream B Recycle
Stream A WTE · Stream B Recycle
↓
VRM Pulverizer
SHRD-APZ-001/002 · P80 <500 µm · ATEX Z21
SHRD-APZ-001/002 · P80 <500 µm · ATEX Z21
↓
Loss-in-Weight Feeders
SHRD-LWF-001–004 · ±0.5% accuracy
SHRD-LWF-001–004 · ±0.5% accuracy
→
Blending and Metering
Rotational Mixer
SHRD-MXR-001/002 · AFR = 0.25 · CV <5%
SHRD-MXR-001/002 · AFR = 0.25 · CV <5%
↓
Regenesis Feed Bin
SHRD-RFB-001/002
SHRD-RFB-001/002
↓
To Regenesis MCR
~409 TPD blended · AFR confirmed
~409 TPD blended · AFR confirmed
Shredder Train sequence from Trough 1 discharge to Regenesis Feed Metering Bin. N+1 redundancy applies to Primary Shredder, Hammermill, and VRM Pulverizer. APS Capture Stream runs parallel to all enclosed zones (not shown).
DIAG-SHRD-002
Trough 2 NIR Moisture Routing — Decision Logic
Decision Tree
NIR Moisture Sensor — Trough 2 Discharge Conveyor
SCADA Routes Material Based on NIR Reading + Material Type
ASH PATH
Moisture below 15% — Bypass Dryer
Moisture 15 to 30% — Dryer Trim Cycle
Moisture above 30% — Full Dryer Cycle
↓
Lumpbreaker / Cage Mill
↓
VRM Pulverizer — P80 below 500um
↓
Ash Silo ASL-001
SLUDGE PATH
Moisture below 15% — FLAG ANOMALOUS — Supervisor Review
Moisture 15 to 60% — Pre-Dewatering
Moisture above 60% — Pre-Dewatering MANDATORY
↓
Paddle Dryer — 130 to 160 deg C
↓
Impact / Pin Mill Pulverizer
↓
Sludge Silo ASL-002
Both silos — Pneumatic transfer to Shredder Train — Rotational Mixer at AFR 0.25
SCADA executes this routing logic automatically on NIR reading. Manifest-declared material type supplements the NIR reading. Operator may override any gate position from HMI at any time. All routing decisions logged with timestamp for audit trail.
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 Shredder Train is engineered as a closed-loop manufacturing subsystem designed for near-zero emissions, near-zero discharge, and near-zero residual. All process enclosures operate under continuous negative pressure. There is no routine atmospheric discharge from any module in this group. The APS recovers all airborne particulates and vapors as product streams via continuous negative-pressure capture.This TDS defines the engineering basis for the Carbotura Pregenesis Protocol Shredder Train, covering Modules 1 through 4: Primary Shredding, Hammermill size reduction, Ash Pulverizer (VRM), and Rotational Mixer blending system. The Shredder Train processes up to 1,000 TPD of Manufacturing Feedstock (MSW) blended with WTE bottom ash and/or Regenesis recirculated solids at a design Ash-to-Feedstock Ratio (AFR) of 0.25. The blended material is size-reduced to P80 <25 mm and homogenized before entering the downstream Regenesis MCR Reactor.
The module operates as two parallel process paths converging at the Rotational Mixer: the main Manufacturing Feedstock path (size reduction and two-stage ferrous separation) and the ash susceptor path (pulverizing, storage, and precision metering). Combined two-stage ferrous removal achieves ≥99% efficiency for ferrous items ≥10 mm, protecting downstream equipment and ensuring a clean OmniCrude™ feed stream.
Rev 1 upgrades this document from Class 4 Preliminary to Class 2 OEM Engineering Release. The full ICD register for Modules 1–4 is established herein for the first time (7 ICDs, all DEFINED). Skid-Integrated Spring Isolation is specified for SHRD-SHR-001/002 and SHRD-HMR-001/002, eliminating all isolated slab section requirements. The Authorized Strategic Integrator (ASI) role replaces all vendor-specific integrator references, maintaining multi-ASI qualification flexibility.
2. Facility Context & Module Boundaries
| Boundary | Definition |
|---|---|
| Upstream Boundary | Trough 1 lift conveyor discharge — point at which shredded Manufacturing Feedstock is received from Module 0B (CBT-PRE-TDS-002) |
| Downstream Boundary | Regenesis Feed Metering Bin (SHRD-RFB) discharge — point of handoff to the Regenesis Protocol |
| Exclusions | Building structure, APS external ductwork, explosion vent civil routing, fire suppression water deluge, Owner's Engineer scope |
3. Process Description
3.3 Mass Balance (AFR = 0.25 Design Point)
| Stream | Description | Rate (TPD as-received) | Notes |
|---|---|---|---|
| Manufacturing Feedstock In | MSW received from Trough 1 / Module 0B | 1,000 | Design basis |
| Ash In — Stream A | WTE bottom ash, external supply | ~175 | At AFR=0.25; Stream B provides balance |
| Ash In — Stream B | Regenesis solids recycle, internal | ~75 | 80–120 TPD range |
| Total Ash In | Combined at AFR=0.25 | 250 | = 1,000 × 0.25 |
| Ferrous Removed — Stage 1 | Post-primary shredder, MFS-001/002 | ~28–40 | 2.8–4.0% of Manufacturing Feedstock (P50) |
| Ferrous Removed — Stage 2 | Post-hammermill, MFS-003/004 | ~8–10 | Residual fine fragments |
| Total Ferrous Removed | Combined two-stage extraction | ~36–50 | Co-manufactured revenue stream |
| Blended Feed to Regenesis | Homogeneous blend to SHRD-RFB | ~1,200–1,214 | 1,000 + 250 − 36 to 50 TPD ferrous |
3.4 Key Process Parameters
| Parameter | Design Value | Alarm Low | Alarm High |
|---|---|---|---|
| Primary shredder output size (P80) | 150 mm (6 in.) | — | >200 mm sustained |
| Hammermill screen aperture | 25 mm (1 in.) | — | Screen bypass detected |
| AFR setpoint (default) | 0.25 | <0.10 (process alert) | >1.0 (hard limit) |
| Ash pulverizer output | <500 µm D90 | — | >600 µm D90 |
| Blending uniformity (CV) | <5% | — | >8% (alarm) |
| Building negative pressure | –0.075 in. WC (mid-range) | <–0.05 in. WC | >–0.10 in. WC |
| AFR accuracy (SCADA) | ±0.02 of setpoint | — | Deviation >0.02 for >2 min |
5. Canonical AFR Definition
AFR Canonical Definition — Applied to All Carbotura Technical Documents and SCADA Control Logic
AFR = mash / mfeedstockWhere mash = mass flow of ash (WTE + Regenesis solids) and mfeedstock = mass flow of MSW Manufacturing Feedstock only. The denominator is Manufacturing Feedstock mass only — NOT total blended mass. Default design AFR = 0.25 (250 TPD ash per 1,000 TPD Manufacturing Feedstock).
| AFR | Ash (TPD) | Feedstock (TPD) | Total Blend (TPD) | Ash % of Blend |
|---|---|---|---|---|
| 0.00 | 0 | 1,000 | 1,000 | 0.0% |
| 0.10 | 100 | 1,000 | 1,100 | 9.1% |
| 0.25 (Design) | 250 | 1,000 | 1,250 | 20.0% |
| 0.50 | 500 | 1,000 | 1,500 | 33.3% |
| 1.00 | 1,000 | 1,000 | 2,000 | 50.0% |
6. Module Equipment Specifications
6.1 Primary Shredder SHRD-SHR-001/002 — Including Skid-Integrated Spring Isolation
Skid-Integrated Spring Isolation Mandate — CED-MECH-003
SHRD-SHR-001/002 incorporates a factory-poured inertia base and kinetic spring isolation mounts within the skid boundary per ASI-ISO-SHRD-SHR-001/002. No isolated slab sections, embedded spring rails, or field-poured inertia blocks are required or permitted at the site. Standard facility slab per DUMP-BLD-001 is the complete civil interface. Full specification in CBT-PRE-ICD-001 Rev 1 Section 5 →Primary Shredder SHRD-SHR-001/002
Cutter Gap
150 mm
Hook Geometry
Aggressive hook, 8-hook rotor configuration
Nominal Output P80
150 mm (6 in.) — empirical OEM basis
Throughput per Unit
40–60 TPH (MSW, as-received)
Drive
Hydraulic, variable speed
Motor
290 kW P50, 380 kW peak
Redundancy
2× units — 1 operating + 1 standby/parallel — 50% duty cycle
Spring Isolation System
ASI-ISO-SHRD-SHR-001/002 — 3.0 in. static deflection; fn 0.85–0.95 Hz; ≥93% isolation efficiency at 2 Hz; 8× Kinetics SLF mounts per unit; factory-poured inertia base 28,000–34,000 lb within skid frame
APS Connection
Sealed Hardox enclosure, negative-pressure extraction port
APS CFM Normal / Peak
1,200 / 2,000 CFM — process-capture basis only
6.2 Hammermill SHRD-HMR-001/002
Hammermill SHRD-HMR-001/002
Output Target
P95 ≤ 25 mm (1 in. screen aperture)
Grizzly Opening
50 × 50 mm
Design Recirculation
5% of feed rate; alarm at >5% sustained for >10 min
Throughput per Unit
40–55 TPH
Motor
265 kW P50, 330 kW peak
Redundancy
2× units — 1 operating + 1 standby — 50% duty cycle
Spring Isolation
ASI-ISO-SHRD-HMR-001/002 — 2.0 in. deflection; fn ~1.1 Hz; ≥98% isolation at 15 Hz; 6× mounts per unit; factory-poured inertia base 22,000–26,000 lb
APS CFM Normal / Peak
1,500 / 2,500 CFM — process-capture basis only
6.3 Ash Pulverizer — VRM SHRD-APZ-001/002
Ash Pulverizer (Vertical Roller Mill) SHRD-APZ-001/002
Technology
Vertical Roller Mill (VRM) — Pfeiffer MPS or Loesche LM series
Output Specification
<500 µm D90
Specific Energy
15–22 kWh/t (WTE ash); 18–28 kWh/t (Regenesis char) — [Calculated — basis: Pfeiffer/Loesche OEM grindability test data; confirmation required per Open Action ICD-A02]
Motor
185 kW P50, 235 kW peak
N₂ Inerting
Zone Z-03 — 99.9% N₂ at 7 bar; 60 Nm³/hr normal via ASI-OCB-FLG-4IN-RF150
APS CFM Normal / Peak
800 / 1,400 CFM — ATEX-rated sealed enclosure; combustible dust classification
Condition Precedent
OEM grindability test required pre-procurement ($15K–$25K). Must complete before final VRM equipment order. Open Action ICD-A02.
6.4 Rotational Mixer SHRD-MXR-001/002
Rotational Mixer SHRD-MXR-001/002
Type
Rotational / paddle mixer, continuous
Blending Target
CV <5% (Coefficient of Variation of blend uniformity)
Throughput
Up to 60 TPH blended feed per unit
Motor
115 kW P50, 155 kW peak
APS CFM Normal / Peak
600 / 1,000 CFM — drum end seal extraction ports
9. Modular Installability & Interface Control
ICD Rev 1 — Full Register Established
The complete ICD register for Modules 1–4 is published herein for the first time. All 7 ICDs are DEFINED. Interface Readiness Level upgraded from IRL 5–6 (Rev 0 conceptual) to IRL 8 (Rev 1 FEED-validated). See full specification: CBT-PRE-ICD-001 Rev 1 →| Interface | ICD Reference | Connection Type | Status |
|---|---|---|---|
| Module 0B lift conveyor → SHRD upstream handoff | ICD-SHRD-UP-001 | Flanged AR400 chute + E-stop SIL 1 + Modbus TCP feed rate | DEFINED — Rev 1 |
| Facility 32 MW PowerBlock → SHRD MCC | ICD-SHRD-PWR-001 | ASI-PBK-QC-4160-32MW + ASI-PWR-480-3PH-60A per skid | DEFINED — Rev 1 |
| Shredder Train SCADA → Facility SCADA Master | ICD-SHRD-DAT-001 | Modbus TCP/IP — ASI-DAT-MOD-TCP-M12 per skid | DEFINED — Rev 1 |
| All 9 APS capture points → APS Common Header | ICD-SHRD-APS-001 | 9× ASI-APS-FLG + N₂ supply flange + Modbus TCP VAV control | DEFINED — Rev 1 |
| WTE Ash Stream A trucks → SHRD-ASL silos | ICD-SHRD-ASH-001 | ASI-OCB-FLG-4IN-RF150 silo nozzles + pneumatic transfer | DEFINED — Rev 1 |
| SHRD-RFB → Regenesis Protocol MCR | ICD-SHRD-DN-001 | ASI-OCB-FLG-8IN-RF150 + ASI-DAT-MOD-TCP-M12 metering rate | DEFINED — Rev 1 |
| Facility PSA N₂ Generator → SHRD inerting system | ICD-SHRD-N2-001 | ASI-OCB-FLG-4IN-RF150 + Modbus TCP low-flow interlock SIL 1 | DEFINED — Rev 1 |
10. Utilities Register & Energy Balance
10.1 Electrical Load Schedule
| Equipment | Tag | Units Active | P50 kW | P90 (Peak) kW |
|---|---|---|---|---|
| Tire Pre-Shredder | TPS-001 | 1 | 175 | 235 |
| Primary Shredder | SHR-001/002 | 1+1 | 290 | 380 |
| Shredder HPU | SHR-HPU-001 | 1 | 30 | 45 |
| Mag. Sep. — Post-Shredder | MFS-001/002 | 1+1 | 5 | 7 |
| Hammermill | HMR-001/002 | 1+1 | 265 | 330 |
| Ash Pulverizer VRM | APZ-001/002 | 1+1 | 185 | 235 |
| Rotational Mixer | MXR-001 | 1 | 115 | 155 |
| Loss-in-weight feeders | LIW-001/002 | 2 | 15 | 22 |
| Mag. Sep. — Post-Hammermill | MFS-003/004 | 1+1 | 5 | 7 |
| Conveyors (all) | CV-xxx | — | 87 | 112 |
| Instruments / Controls | — | — | 15 | 20 |
| SUBTOTAL CORE | — | — | ~1,185 | ~1,546 |
12. CAPEX Estimate
AACE Classification — Class 2 (±15%) | 2026 USD
Upgraded from Class 4 ±30% (Rev 0) to Class 2 ±15% (Rev 1). Estimating methodology: factored/parametric — equipment costs from budget quotes (3+ OEMs per category), ROM quotes, and published industry benchmarks.| Item | Low ($M) | High ($M) | Basis |
|---|---|---|---|
| Primary Shredders (2×) incl. Spring Isolation | 1.8 | 3.2 | Budget quotes — Vecoplan, Lindner, SSI; spring isolation per ASI-ISO spec |
| Hammermills (2×) incl. Spring Isolation | 1.2 | 2.4 | Budget quotes — Stedman, Metso; spring isolation per ASI-ISO spec |
| VRM Ash Pulverizers (2×) | 2.0 | 3.8 | Budget quotes — Pfeiffer MPS, Loesche LM; pending grindability test confirmation |
| Rotational Mixer (1×) | 0.6 | 1.2 | Budget quotes — Readco, BHS-Sonthofen |
| Tire Pre-Shredder (1×) | 0.5 | 0.9 | Budget quote |
| Magnetic Ferrous Separators (4×) | 0.15 | 0.38 | Budget quotes — Eriez, Bunting |
| Feeders, Conveyors, Silos | 1.0 | 1.8 | Parametric estimate |
| Electrical (MCC, cabling) | 0.8 | 1.5 | Factor estimate — 15% of equipment |
| SCADA / Controls | 0.5 | 1.0 | Factor estimate |
| Modular Assembly & erection | 1.2 | 2.2 | Factor estimate — 20% of equipment |
| Commissioning & startup | 0.3 | 0.6 | OEM supervision rates |
| First fill spares | 0.3 | 0.5 | 5% of equipment |
| Contingency (15%) | — | 0.6 | Applied to total per AACE Class 2 |
| TOTAL TDS-003 CAPEX | $10.4M | $20.1M | Class 2 ±15% | AACE 18R-97 | 2026 USD |
13. TRL / ERL / IRL Assessment
| Module | TRL | ERL | IRL | Notes |
|---|---|---|---|---|
| Primary Shredder | 9 | 8 | 8 | Fully commercial; multiple OEM references (Vecoplan, Lindner operating records) |
| Hammermill | 9 | 8 | 8 | Fully commercial; MSW-proven (Stedman, Metso operating data) |
| VRM Ash Pulverizer | 7–8 | 7 | 7 | Commercial for minerals; MSW ash application requires grindability confirmation (Open Action ICD-A02) |
| Rotational Mixer | 8 | 7 | 8 | Commercial for bulk blending; IRL upgraded Rev 1 with full ICD definition |
| Tire Pre-Shredder | 9 | 8 | 8 | Fully commercial; tire recycling industry heritage |
| Magnetic Ferrous Separators (4×) | 9 | 8 | 8 | Mature commercial technology; Eriez/Bunting OEM data |
| Integrated System | 7 | 7 | 8 | IRL upgraded from 5–6 to 8 with full ICD register definition (Rev 0→Rev 1) |
14. Confidence Factor
| Dimension | Score | Max | Basis |
|---|---|---|---|
| Equipment selection maturity | 9 | 10 | Budget quotes from 3+ OEMs per category |
| Process design basis | 9 | 10 | AFR canonical definition; feedstock envelope complete |
| Energy balance closure | 9 | 10 | Full parasitic loads included in Section 10 |
| Integration readiness (ICD) | 9 | 10 | Full ICD register established Rev 1; IRL upgraded to 8 |
| Availability / reliability | 7 | 10 | Model complete; industry benchmarks cited |
| Safety / DHA | 7 | 10 | Preliminary DHA; formal NFPA 652 DHA pending (Open Action ICD-A04) |
| Environmental (APS) | 8 | 10 | Preliminary design complete; all capture points defined |
| Cost estimate maturity | 8 | 10 | Class 2 ±15% achieved |
| TOTAL | 66/80 | 80 | Confidence Factor: 82.5% — Good / Investor-bankable |
17. Risk Register
| Risk ID | Category | Severity | Mitigation |
|---|---|---|---|
| R-01 | VRM grindability test pending — APZ specification uncertain | MEDIUM | Open Action ICD-A02: OEM grindability test ($15K–$25K) required before APZ procurement release. Pfeiffer and Loesche test capability available. Results expected within 4–6 weeks of test authorization. |
| R-02 | Primary shredder lead time at 26–32 weeks — schedule critical | MEDIUM | Early procurement authorization. Parallel competitive bids from Vecoplan, Lindner, SSI. ICD-SHRD-UP-001 finalization prior to fabrication release. |
| R-03 | Combustible dust hazard at APZ / SHRD-ASL zones — safety / regulatory | HIGH | Preliminary DHA completed; formal NFPA 652 DHA in progress (Open Action ICD-A04). Z-03/Z-04 zones N₂-inerted per ICD-SHRD-N2-001. Combustible dust classification drives ATEX-rated enclosures for all APZ equipment. |
| R-04 | Li-battery in Manufacturing Feedstock — fire / thermal runaway in shredder | HIGH | Thermal camera screening at TISAB approach (upstream — Module 0A). Quarantine bay protocol. CO monitoring trigger at primary shredder. Water deluge at QA-01 bay. NFPA fire suppression throughout building. |
| R-05 | AFR accuracy deviation — OmniCrude™ yield impact | MEDIUM | Dedicated belt scale on feedstock path. Loss-in-weight feeders with ±0.5% accuracy. SCADA AFR alarm at ±0.02 deviation for >2 minutes. RevCon warranty clause triggered at AFR deviation ≥0.05. |
END OF DOCUMENT — CBT-PRE-TDS-003 | 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%