Working Document — Pre-Release Engineering Development
This document is a working specification. PE release requires Lead Systems Architect authorization.
ARM-2026-002 incorporated. T2-PDR superseded by T2-ITD. WHSG thermal source (200–400°C) via NXS-Z2 replaces steam header.
| Document Number | CBT-PRE-TDS-004 |
| Revision | Rev 3 — April 2026 |
| Case Selection | Case 2 — Post-Centrifuge (CONFIRMED at OER Gate 1). Decanter centrifuges pre-dewater sludge to ~25–30% DS before drying. T2-ITD sized accordingly — 36× smaller than Case 1. |
| Rev 3 Change Summary | ARM-2026-002 Cluster E: T2-PDR → T2-ITD throughout. Thermal input: WHSG High-Temp Thermal (200–400°C) via NXS-Z2 per ARM-2026-002 Cluster F. ICD-WHSG-T2ITD-001 added. NEXUS zone load schedule added. Vendor matrix updated: LCI Corp shortlisted for T2-ITD. S4-R6: ASI generic throughout. |
| Governing ECNs | CBT-PRE-OER-AMD-001 Rev 1 · CBT-PRE-ECN-003 Rev 1 · ECN-004 · ECN-005 |
| Governing ARMs | ARM-2026-001 · ARM-2026-002 |
| Revenue Baseline | RevCon 3 — $150M–$325M/yr, 400 TPD baseline |
| Chairman | Allen Witters |
1. Executive Summary
Case 2 Selection — CONFIRMED at OER Gate 1
T2 Processing is designed for Case 2 — post-centrifuge dewatering prior to Indirect Thermal Dryer. Decanter centrifuges pre-dewater sludge to ~25–30% DS before drying. This reduces T2-ITD size by ~36× vs. Case 1 (direct drying). Case 2 is the governing design basis for all equipment specifications and CAPEX in this document.
T2 Lumpbreaker Kinetic Isolation (ARM-2026-001)
T2 Lumpbreakers incorporate ASI-ISO-LBK-001 integrated neoprene isolation pads and steel inertia frame within skid boundary. Static deflection: 1.5 in. (38 mm). Rated load: 8 tons/unit. Vibration trip: ≤7 mm/s RMS (ISO 10816-3) to module PLC. Site civil = standard slab.
This TDS defines engineering requirements for Module T2 — Trough 2 Processing. T2 receives sludge and Enhancement Admix manufacturing feedstock from Trough 2 and liquid biosludge from Module 0D, processes it through dewatering, indirect thermal drying, and pulverizing stages, and delivers <500 μm dry Enhancement Admix and sludge char to the Shredder Train Enhancement Admix circuit for EAF blending.
All throughput guarantees and performance metrics are baselined to RevCon 3: $150M–$325M/yr revenue floor at 400 TPD baseline factory configuration. Carbotura Inc. holds all design authority. The ASI (vendor pending D-ASI-01) holds no design authority.
2. Facility Context & Module Boundaries
| Upstream inputs | Trough 2 sludge/Enhancement Admix feedstock (CBT-PRE-TDS-002 §5.5) · Liquid biosludge from Module 0D (CBT-PRE-ECN-003) via LBS-MNF-001 to Trough 2 liquid inlet port |
| Downstream output | <500 μm dry Enhancement Admix + sludge char → SHRD-APZ/EAS Enhancement Admix circuit (CBT-PRE-TDS-003) via pneumatic transfer (4-in. 316L SS) |
| Thermal input (cross-protocol) | WHSG High-Temperature Thermal (200–400°C steam or thermal oil) from REG-WHSG-001 via NXS-Z2-FLUID; connector ASI-THM-HT; ICD-WHSG-T2ITD-001 |
| Leachate output | Centrifuge and T2-ITD condensate → Liquifact collection manifold → PRE-LFB-001 → PRE-EVP-001 |
| APS connections | All T2 dryer vapor captures, lumpbreaker dust connections to APS via ASI-APS-FLG |
| NEXUS zones | NXS-Z1-ELEC (power + data) · NXS-Z2-FLUID (WHSG High-Temp Thermal + cooling) · NXS-Z3-GAS (N², instrument air) · NXS-Z4-MAT (APS ductwork + pneumatic transfer) |
3. Process Description — Case 2
| Step | Equipment | Action | Output State | Key Param |
|---|
| 1 | Trough 2 Feed | Sludge/Enhancement Admix/liquid feed from Trough 2 walking floor + Module 0D liquid inlet | Mixed wet sludge + Enhancement Admix; 60–85% moisture | NIR routes by DS% |
| 2 | Lumpbreaker (T2-LBK-001/002) | Reduces lumpy Enhancement Admix to <25 mm. ASI-ISO-LBK-001 isolation. | <25 mm Enhancement Admix + wet sludge | Vibration trip ≤7 mm/s |
| 3 | Decanter Centrifuge (T2-DCN-001/002) | Pre-dewaters sludge fraction to ~25–30% DS. Centrate to Liquifact system. | ~25–30% DS sludge cake | Polymer conditioning required |
| 4 | Polymer Conditioning (T2-PCM-001) | Inline polymer dosing to sludge before centrifuge. Improves DS% and cake release. | Conditioned sludge | Polymer: 4–10 kg/ton DS |
| 5 | Indirect Thermal Dryer (T2-ITD-001/002) | High-temperature indirect thermal drying. WHSG thermal input 200–400°C via NXS-Z2. Reduces sludge cake to <10% moisture. | Dry sludge char; <10% moisture | WHSG thermal 200–400°C; 1.2–1.5 kg thermal equiv./kg H&sub2;O evaporated |
| 6 | Impact Mill / VRM Pulverizer (T2-IMP/VRM) | Pulverizes dried Enhancement Admix and sludge char to <500 μm. | <500 μm at P90 | Grindability-dependent |
| 7 | Pneumatic Transfer (T2-PNT-001) | Transfers <500 μm product to SHRD-EAS silos via 4-in. 316L SS line. | Enhancement Admix/char at SHRD-EAS inlet | 80 psi max transfer pressure |
3.2 Mass Balance (Case 2, 400 TPD Canonical Basis)
| Trough 2 input | ~160 TPD wet sludge + Enhancement Admix (400 TPD proportional to nameplate) |
| Module 0D liquid input | Variable — routed per DS% threshold |
| Centrifuge water removal | ~70–80 TPD centrate to Liquifact system |
| T2-ITD evaporation | ~30–40 TPD water vapor to APS condensate recovery |
| Pneumatic output to SHRD-EAS | ~50–70 TPD dry Enhancement Admix + sludge char <500 μm |
4. Feedstock Design Envelope
| Parameter | P50 | P90 (Design Limit) |
|---|
| Sludge inlet DS% | 2–8% | Up to 12% (liquid biosludge from Module 0D) |
| Sludge particle size | <5 mm | <25 mm |
| Sludge moisture | 70–82% | Up to 85% |
| Enhancement Admix moisture | 8–20%; particle <50 mm lumps | Up to 30%; particle <75 mm |
| Enhancement Admix SiO&sub2; | 30–45% | Up to 50% |
| DS routing threshold (Module 0D) | DS≥8%: Trough 2 decanter path · DS<8%: bypass decanter → T2-ITD surge tank directly |
5. Module Equipment Specifications
5.1 T2-LBK-001/002 — Enhancement Admix Lumpbreakers + ASI-ISO-LBK-001
Kinetic Isolation: ASI-ISO-LBK-001
Steel inertia frame with neoprene isolation pads; 4-point arrangement; 1.5 in. static deflection; 8 tons rated load; vibration trip ≤7 mm/s RMS (ISO 10816-3) to module PLC.
| Tag | T2-LBK-001 / T2-LBK-002 |
| Type | Single-rotor cage mill (lumpbreaker) |
| Design capacity | Up to 200 TPD input (T2 Enhancement Admix fraction); 50% duty cycle |
| Output | <25 mm Enhancement Admix lumps for centrifuge and dryer feed |
| Motor | 22–37 kW; VFD; ATEX Zone 22 |
| Kinetic isolation | ASI-ISO-LBK-001: neoprene pad mounts, 1.5 in. static deflection, 8 tons/unit, steel inertia frame; vibration trip ≤7 mm/s RMS to PLC |
| CAPEX [Class 2 ±15%] | $160K–$360K per unit |
5.2 T2-DCN-001/002 — Decanter Centrifuges
| Tag | T2-DCN-001 / T2-DCN-002 |
| Type | Horizontal scroll decanter centrifuge; continuous; polymer-conditioned sludge duty |
| Design capacity | Each unit rated for full T2 sludge fraction; 50% duty cycle |
| Output (DS%) | 25–30% DS sludge cake from 2–12% DS feed (Case 2 design basis) |
| Motor | 37–55 kW main bowl motor; 15–22 kW back-drive; VFD both; ATEX Zone 22 |
| MOC | 316L SS bowl and scroll; hard-facing on scroll flights for abrasion resistance |
| Polymer integration | Inline polymer dosing at centrifuge inlet (T2-PCM-001) |
| CAPEX [Class 2 ±15%] | $800K–$1,800K per unit |
5.3 T2-ITD-001/002 — Indirect Thermal Dryers
OPEN — ICD-WHSG-T2ITD-001 (OER Gate 2)
T2-ITD sizing requires: (1) D-13 resolved (WHSG thermal budget confirmed); (2) D-THM-01 resolved (WHSG steam parameters); (3) LCI Corp and second vendor OEM quotes. CAPEX range maintained pending OEM quote.
| Tag | T2-ITD-001 / T2-ITD-002 |
| Type | Indirect Thermal Dryer (ITD) — high-temperature thermal input, 200–400°C |
| Case 2 sizing | Sized for post-centrifuge feed (~25–30% DS input). 36× smaller than Case 1. |
| Thermal source | WHSG High-Temperature Thermal — REG-WHSG-001 via NXS-Z2-FLUID. Steam or thermal oil, 200–400°C. Connector: ASI-THM-HT. ICD: ICD-WHSG-T2ITD-001. |
| Thermal duty | 1.2–1.5 kg thermal equivalent per kg H&sub2;O evaporated (parametric) |
| Output | <10% moisture dry sludge char at rated throughput |
| Vapor management | Fully enclosed vapor capture; ASI-APS-FLG connection at vapor outlet; 400 CFM normal / 700 CFM peak per unit. Temperature: 80–150°C vapor. |
| OEM shortlist | LCI Corp (horizontal and/or vertical evaporator dryer) + minimum one additional US manufacturer per American Manufacturing Preference Policy |
| CAPEX [Class 2 ±15%] | $1,600K–$5,000K per unit (range maintained pending LCI Corp + second vendor OEM quote) |
5.4 T2-IMP/VRM — Impact Mill / VRM Pulverizer
| Type | Impact mill or vertical roller mill; application-selected at OEM Gate 2 per Enhancement Admix grindability test |
| Output | <500 μm at P90 |
| CAPEX | $400K–$1,000K per unit |
6. APS Interface Register
| Capture Point | Normal CFM | Peak CFM | Temp at Capture | Material |
|---|
| T2-LBK enclosure (per unit) | 200 | 400 | Ambient–40°C | Enhancement Admix dust, H&sub2;S traces |
| T2-ITD vapor outlet (per unit) | 400 | 700 | 80–150°C | Water vapor, organic acids, H&sub2;S, VOCs |
| T2 pulverizer (per unit) | 150 | 300 | Ambient–50°C | Sub-500 μm Enhancement Admix powder |
| TOTAL T2 APS | ~1,500 | ~2,500 | — | All T2 capture points combined |
7. Modular Installability & ICD
| ICD Reference | Interface | Connection Type | ASI Standard | Test Requirement | Status |
|---|
| ICD-TR2-T2-001 | T2 inlet from Trough 2 walking floor | AR400-lined inlet hopper; matched to walking floor discharge chute | Carbon steel hopper flange | SAT: material flow continuity; SCADA feed rate signal | DEFINED — Rev 2 |
| ICD-0D-T2-001 | Module 0D liquid inlet | 4-in. 316L SS flange from LBS-MNF-001 to Trough 2 liquid inlet port | 316L SS ANSI 150# RF | SAT: flow continuity; DS% routing to SCADA | DEFINED — Rev 2 |
| ICD-T2-EAS-001 | Enhancement Admix outlet to SHRD-EAS | 4-in. 316L SS pneumatic transfer; 80 psi max; flanged | Pneumatic transfer flange; 316L SS | FPT: <500 μm product at SHRD-EAS inlet verified by sampling | DEFINED — Rev 2 |
| ICD-T2-APS-001 | APS connections — all T2 capture points | ASI-APS-FLG flanged duct at all capture points | ASI-APS-FLG | SAT: negative pressure confirmed at all capture points | DEFINED — Rev 2 |
| ICD-T2-PWR-001 | NXS-Z1-ELEC power — module MCC | 800V DC device link | ASI-PBK-QC | SAT: all drives energized; SCADA confirmed | DEFINED — Rev 3 |
| ICD-T2-DAT-001 | NXS-Z1-ELEC SCADA data | Modbus TCP/IP | ASI-DAT-MOD-TCP | SAT: all T2 process variables visible in facility SCADA | DEFINED — Rev 3 |
| ICD-WHSG-T2ITD-001 | NXS-Z2-FLUID — WHSG High-Temp Thermal to T2-ITD | Steam or thermal oil, 200–400°C; ASI-THM-HT drop at T2-ITD thermal boundary | ASI-THM-HT | FPT: T2-ITD outlet moisture <10% at rated throughput; thermal supply within spec | OPEN — OER Gate 2: D-THM-01 + D-13 |
| ICD-T2-WTR-001 | Process water — CIP and polymer dilution | ASI-WTR-001 | ASI-WTR-001 | SAT: flow continuity at T2-PCM-001 | DEFINED — Rev 2 |
| ICD-T2-N2-001 | NXS-Z3-GAS — N&sub2; inerting (VRM/Impact Mill) | NXS-Z3 drop; pneumatic fitting | Per N&sub2; spec | SAT: N&sub2; pressure confirmed at VRM zone before first run | DEFINED — Rev 3 |
| ICD-T2-LCH-001 | Leachate to Liquifact system | Gravity or pumped; 4-in. 316L SS | 316L SS flange | SAT: zero discharge path confirmed; flow to PRE-LFB-001 confirmed | OPEN — OER Gate 2: water treatment ICD |
NEXUS Zone Connections — Module T2
| Zone | Connection | Connector |
|---|
| NXS-Z1-ELEC | HVDC 800V device feed (all T2 VFD motors); 48V controls | ASI-PBK-QC; ASI-DAT-MOD-TCP |
| NXS-Z2-FLUID | WHSG High-Temp Thermal (T2-ITD); process cooling water | ASI-THM-HT; ASI-WTR-001 |
| NXS-Z3-GAS | N&sub2; (VRM inerting); instrument compressed air | NXS-Z3 drop |
| NXS-Z4-MAT | APS Capture Stream ductwork; T2-PNT pneumatic transfer to SHRD-EAS | ASI-APS-FLG |
8. Utilities Register
NXS-Z1-ELEC — Electrical
| Equipment | P50 Load (kW) | P90 Load (kW) | Notes |
|---|
| T2-DCN-001/002 decanter drives (bowl + back-drive) | 52–77 kW each | 77 kW each | VFD; ATEX Zone 22 |
| T2-ITD-001/002 agitator/drive (per unit) | 22–55 kW each | 55 kW each | OEM-dependent; confirm at sizing |
| T2-LBK-001/002 lumpbreakers | 22–37 kW each | 37 kW each | VFD |
| T2-IMP/VRM-001/002 pulverizers | 45–75 kW each | 75 kW each | VFD |
| T2-PNT-001 pneumatic conveying blower | 30–55 kW | 55 kW | — |
| T2-PCM-001 polymer system | 5–10 kW | 10 kW | — |
| Controls and instrumentation (48V DC) | ~3 kW | ~3 kW | NXS-Z1 48V bus |
| Module T2 TOTAL ELECTRICAL | ~250–420 kW (400 TPD basis) | Dual units at 50% duty; one string running |
NXS-Z2-FLUID — Thermal and Cooling
| Utility | Demand (400 TPD) | Source | Notes |
|---|
| WHSG High-Temp Thermal (T2-ITD primary) | ~320–430 kW thermal (steam or oil equivalent) | REG-WHSG-001 via NXS-Z2; ASI-THM-HT | Replaces all prior steam header references. Parameters OPEN — D-THM-01. |
| Process cooling water | ~2–5 m³/day | NXS-Z2 cooling loop | CIP and seal cooling |
NXS-Z3-GAS and NXS-Z4-MAT
| Zone | Utility | Demand | Notes |
|---|
| NXS-Z3-GAS | N&sub2; inerting (VRM/Impact Mill zone) | Continuous flow at VRM operating pressure | ATEX Zone 22 requirement; flow rate per VRM OEM |
| NXS-Z3-GAS | Instrument compressed air | 80–90 psi; ~20 scfm | Actuated valves, controls |
| NXS-Z4-MAT | APS Capture Stream — total T2 | ~1,500 CFM normal / ~2,500 CFM peak | — |
| NXS-Z4-MAT | Pneumatic transfer to SHRD-EAS (T2-PNT-001) | Per product throughput | 80 psi max |
9. Vendor Matrix
| Equipment | Vendor / OEM | Country | Procurement Path | Lead Time |
|---|
| T2-ITD Indirect Thermal Dryer | LCI Corp | USA | Direct — US Manufacturer | 28–40 wks |
| T2-ITD (alt) | TBD at Gate 2 — second vendor required | Verify at RFQ | Direct or ASI-Integrated | 28–40 wks |
| Decanter Centrifuges | Alfa Laval | Sweden | ASI-Integrated | 20–28 wks |
| Decanter Centrifuges | ANDRITZ | Austria | ASI-Integrated | 20–28 wks |
| Decanter Centrifuges | Flottweg | Germany | ASI-Integrated | 20–28 wks |
| Enhancement Admix Lumpbreakers | Pennsylvania Crusher | USA | Direct — US Manufacturer | 14–20 wks |
| Enhancement Admix Lumpbreakers | Stedman Machine | USA | Direct — US Manufacturer | 14–20 wks |
| VRM / Impact Mill (T2) | Bradley Pulverizer | USA | Direct — US Manufacturer | 28–36 wks |
| VRM / Impact Mill (T2) | Gebr. Pfeiffer | Germany | ASI-Integrated | 28–36 wks |
| Polymer Conditioning (T2-PCM) | Netzsch | Germany | ASI-Integrated | 8–12 wks |
10. CAPEX Estimate
All values: Class 2 (±15%) [2026 USD].
| Line Item | Low [2026 USD] | High [2026 USD] | Basis |
|---|
| Decanter centrifuges (T2-DCN) ×2 | $800K | $1,800K | Alfa Laval ROM |
| Belt filter press (backup option) | $300K | $700K | Parametric; confirm need at OER Gate 2 |
| Polymer conditioning system (T2-PCM) | $80K | $180K | Day tank + dosing pumps; ROM |
| Indirect Thermal Dryers (T2-ITD) ×2 | $1,600K | $5,000K | Range maintained pending LCI Corp + second vendor OEM quote (D-01 open; blocked by D-13) |
| Enhancement Admix Lumpbreakers (T2-LBK) ×2 + ASI-ISO-LBK-001 | $320K | $720K | ROM + isolation mount ROM |
| VRM / Impact mill (T2) ×2 | $400K | $1,000K | Parametric |
| Enhancement Admix storage silos (T2 storage) | $200K | $500K | Carbon steel epoxy lined; parametric |
| Pneumatic transfer (T2-PNT) system | $150K | $350K | To SHRD-EAS silos; parametric |
| Conveyors and transfers (internal) | $400K | $800K | All belt/screw internal; parametric |
| E&I (15%) | $761K | $1,658K | Factor |
| Modular Assembly (15%) | $761K | $1,658K | Factor |
| Contingency (15%) | $761K | $1,658K | Class 2 |
| MODULE T2 TOTAL [Class 2 ±15%] | $6,533K | $16,024K | CAPEX will narrow when T2-ITD OEM quote received at Gate 2 |
11. TIC WBS Reconciliation
| Equipment scope included | All T2-xxx tagged equipment, E&I, MCC, Modular Assembly labor, contingency per Section 10 |
| Excluded | PIMB building (facility civil scope); APS main system (CBT-APS-TDS-001); WHSG thermal supply infrastructure beyond module NXS-Z2 tie-in (Regenesis scope); water treatment module for leachate (Owner scope); commissioning and operator training; OEM grindability test (Owner cost) |
| All-in TIC (Module T2 only) | ~$6.5M–$16.0M [Class 2 ±15%] |
12. Lead Time Schedule
| Equipment | Lead Time (weeks) | Critical Path | Notes |
|---|
| T2-ITD Indirect Thermal Dryers — critical path | 28–40 | YES | Custom-sized to Case 2 feed rate and WHSG thermal input; OEM sizing confirmation required before order. Blocked by D-13 → D-THM-01 → D-01 sequence. |
| Decanter Centrifuges (T2-DCN) | 20–28 | No | Standard commercial; order at OER Gate 2 |
| VRM / Impact Mill (T2) — grindability-dependent | 28–36 | CONDITIONAL | Order ONLY after Enhancement Admix grindability test confirms specification |
| Enhancement Admix Lumpbreakers (T2-LBK) | 14–20 | No | Standard cage mill; available from stock or short-order |
| Polymer conditioning system (T2-PCM) | 8–12 | No | Standard assembly |
| Pneumatic transfer system (T2-PNT) | 10–16 | No | Standard industrial; fabricate to T2 outlet spec |
13. TRL / ERL / IRL Assessment
| System | TRL | ERL | IRL | Assessment Notes |
|---|
| Decanter centrifuges | 9 | 5 | 5 | Mature commercial; municipal biosolids standard |
| Indirect Thermal Dryer (T2-ITD) | 9 | 4 | 3 | LCI evaporator dryer technology is proven; Case 2 scale at T2 throughput and WHSG thermal source requires OEM sizing confirmation. IRL=3 pending WHSG ICD resolution (D-THM-01). |
| Enhancement Admix Lumpbreakers + ASI-ISO-LBK-001 | 9 / 8 | 4 | 4 | Lumpbreaker TRL=9; kinetic isolation factory integration novel |
| VRM / Impact Mill (T2 Enhancement Admix path) | 9 | 4 | 4 | Enhancement Admix grindability test required |
| WHSG→T2-ITD thermal interface | 8 | 3 | 3 | First cross-protocol thermal interface; ICD-WHSG-T2ITD-001 open; D-THM-01 unresolved |
| OVERALL T2 | 8 | 3 | 3 | Gated by T2-ITD OEM sizing, WHSG thermal ICD, and Enhancement Admix grindability test |
14. Confidence Factor
| Factor | Weight | Score | Weighted | Basis |
|---|
| Technology maturity (TRL) | 25% | 8/10 | 20.0% | Decanter and T2-ITD TRL=9; WHSG thermal interface TRL=8 |
| Engineering completeness (ERL) | 20% | 5/10 | 10.0% | T2-ITD Case 2 scale, WHSG parameters, and VRM grindability all OPEN limit score |
| Integration readiness (IRL) | 15% | 5/10 | 7.5% | WHSG→T2-ITD ICD open; D-13 and D-THM-01 unresolved |
| Vendor availability | 15% | 8/10 | 12.0% | LCI Corp shortlisted; all decanter categories 3+ vendors |
| Operational heritage | 15% | 7/10 | 10.5% | Individual equipment proven; WHSG→T2-ITD thermal loop at this scale novel |
| Regulatory / permitting | 10% | 7/10 | 7.0% | Standard industrial equipment; facility permitting Owner scope |
| TOTAL BASE SCORE | 100% | — | 67.0% | Lower vs. Rev 2 reflects correctly acknowledging WHSG ICD as open |
| ADJUSTED (ASI guarantee uplift) | — | — | 75% | Recovers to ACCEPTABLE CONFIDENCE upon D-13 + D-THM-01 resolution. Target: re-score at OER Gate 2 after WHSG ICD closed. |
15. Availability Model
| Equipment | MA (%) | MTBF (hrs) | MTTR (hrs) | Basis |
|---|
| Decanter centrifuges (2×, 50% duty) | 94–97 | 2,000–4,000 | 6–12 | Alfa Laval ALDEC reference: municipal biosolids (2018–2024) |
| Indirect Thermal Dryers T2-ITD (2×, 50% duty) | 93–97 | 2,500–4,000 | 8–16 | LCI Corp evaporator dryer operating reference: industrial thermal drying service. Parametric pending OEM sizing confirmation. |
| Enhancement Admix Lumpbreakers (2×, 50% duty) | 95–98 | 3,000–5,000 | 4–8 | Pennsylvania Crusher cage mill reference: industrial mineral duty |
| VRM / Impact Mill (2×, 50% duty) | 93–96 | 2,500–4,000 | 8–12 | Gebr. Pfeiffer VRM reference: industrial mineral/cement duty |
| SYSTEM OA (N+1 across all stages) | 91–95 | N/A | N/A | N+1 on all process-critical equipment. Primary external dependency: WHSG thermal supply from Regenesis — WHSG availability governs T2-ITD uptime. |
16. Risk Register
R-01 MEDIUM — T2-ITD OEM Sizing at Case 2 Scale (Process/Performance)
WHSG thermal source confirmed; OEM sizing at Case 2 feed rate not yet confirmed by LCI Corp or second vendor. Mitigation: (1) Issue RFQ to LCI Corp with confirmed thermal input spec after D-13 resolved; (2) Require OEM to provide performance guarantee with sizing; (3) CAPEX high estimate ($5.0M/unit) accommodates scale uncertainty until Gate 2.
R-02 HIGH — WHSG Thermal Supply Integration (Integration/ICD)
D-13 (Liquifact injection) unresolved — WHSG thermal budget to NXS-Z2 is not confirmed. If Liquifact injection consumes a significant fraction of WHSG output, T2-ITD thermal supply may be constrained. Mitigation: (1) Resolve D-13 as Session 5 first priority; (2) T2-ITD OEM specify acceptable thermal input range with derating curve; (3) If WHSG budget insufficient: supplement with Zero-E Thermal Recovery Stream for pre-heating duty.
R-03 LOW — Lumpbreaker Vibration at High Enhancement Admix Lump Fraction (Safety)
High-lump WTE-derived Enhancement Admix (>75 mm P90) could exceed lumpbreaker capacity. Mitigation: (1) ASI-ISO-LBK-001 vibration trip ≤7 mm/s protects equipment and triggers automatic stop; (2) Oversize lump screen at T2 inlet upstream of lumpbreaker.
R-04 MEDIUM — Enhancement Admix Grindability (Process/Performance)
VRM/Impact Mill specification for T2 cannot be finalized without Enhancement Admix grindability test. Mitigation: (1) Collect Enhancement Admix samples from Owner feedstock source before OER Gate 2; (2) Schedule parallel grindability tests with Bradley Pulverizer and Gebr. Pfeiffer; (3) Contract T2 VRM with performance guarantee conditioned on test results.
17. Spares Register
| Crit. | Equipment | Qty First Fill | Qty Operating | Notes |
|---|
| A | Decanter centrifuge scroll hard-facing (per unit) | 2 scroll sets | 1 set/18 months | Wear item in abrasive sludge/Enhancement Admix service |
| A | T2-ITD thermal seal and rotor wear components (per unit) | 1 full set per unit | Per OEM PM schedule | High-temperature service; OEM-specified replacement interval — confirm at Gate 2 |
| A | ASI-ISO-LBK-001 neoprene isolation pads (per lumpbreaker) | 2 full pad sets | Per degradation | Replace when static deflection deviates >10% from 1.5 in. nominal |
| B | VRM grinding roller wear segments (per mill) | 1 full set | 1 set/18 months | High-wear item on Enhancement Admix duty |
| B | Decanter centrifuge bearing sets (per unit) | 1 set | Per failure | Critical rotating equipment; stock at commissioning |
| B | Polymer dosing pump diaphragms (T2-PCM-001) | 4 diaphragms | Per failure | Standard item; short lead time |
| C | Pneumatic transfer line wear elbows (T2-PNT-001) | 2 sets | Per wear | 316L SS; replace at >50% wall thickness wear |
18. Warranty Register
| Equipment | Warranty Period | OEM Guarantee | Coverage / Notes |
|---|
| Decanter Centrifuges (T2-DCN) | 24 months | Yes — OEM | Parts and labor; scroll hard-facing wear excluded after 12 months |
| Indirect Thermal Dryers (T2-ITD) | 18–24 months | Yes — OEM (LCI Corp preferred; second vendor required) | Parts and labor; thermal performance guarantee (<10% moisture output) contingent on WHSG thermal supply within spec per ICD-WHSG-T2ITD-001. |
| Enhancement Admix Lumpbreakers (T2-LBK) + ASI-ISO-LBK-001 | 18 months | Yes — ASI | ASI integrates lumpbreaker + ASI-ISO-LBK-001 as single warranted skid assembly. Rotor wear excluded after 6 months. Unitized Warranty Passport issued at FAT. |
| VRM / Impact Mill (T2) | 18–24 months | Yes — OEM | Performance guarantee: <500 μm at P90 conditioned on Enhancement Admix grindability within test-confirmed basis. |
| Polymer Conditioning System (T2-PCM-001) | 18 months | Yes — OEM | Dosing accuracy guarantee ±2% at setpoint. Diaphragm wear excluded after 6 months. |
END OF DOCUMENT — CBT-PRE-TDS-004 | Rev 3 | April 2026 | CONFIDENTIAL — CARBOTURA INC.
Case 2 CONFIRMED | ARM-2026-002 Incorporated | T2-ITD (LCI Corp) | WHSG 200–400°C | RevCon 3 Baseline
