Pregenesis Protocol — Technical Design Specification
Liquifact Collection, Evaporation & Distillate Recovery
PRE-LFB-001 Liquifact Collection Buffer · PRE-EVP-001 Forced-Circulation Evaporator (2× Redundant Pair). WHSG thermal source confirmed. Distillate to REG-WHSG-001 feedwater.
Working Document — Pre-Release Engineering Development
This document is a working specification. PE release requires Lead Systems Architect authorization. ARM-2026-002 incorporated. Thermal source confirmed: WHSG High-Temperature Thermal Recovery via NXS-Z2. D-THM-01 CLOSED PARAMETRIC (200–400°C / 10–40 bar). Open: D-11 (LFB→EVP connector), D-17 (concentrate routing), D-23 (buffer hold time), D-24 (NXS-Z2 cross-zone routing).
| Document Number | CBT-PRE-TDS-005 |
| Revision | Rev 0 — April 2026 |
| Scope | PRE-LFB-001 Liquifact Collection Buffer · PRE-EVP-001 Liquifact Evaporator (2× Redundant Pair) |
| Rev 0 Change Summary | Initial release. Scope confirmed Session 5 (D-13, D-16 closed). Thermal source confirmed: WHSG High-Temperature Thermal Recovery via NXS-Z2 (D-16). D-THM-01 closed parametric (Session 7): 200–400°C / 10–40 bar. D-35 closed parametric (Session 7). Open: D-11 (LFB→EVP connector), D-17 (concentrate routing), D-23 (buffer hold time), D-24 (NXS-Z2 cross-zone routing). |
| Governing ECNs | CBT-PRE-OER-AMD-001 Rev 1 · ECN-004 |
| Governing ARMs | ARM-2026-001 · ARM-2026-002 |
| Revenue Baseline | RevCon 3 — $150M–$325M/yr, 400 TPD baseline |
| Nameplate Capacity | ~150 TPD Liquifact at nameplate (1,000 TPD PIMB nameplate) |
| Chairman | Allen Witters |
1. Executive Summary
Near-Zero Design Intent
The Liquifact Collection and Evaporation System is engineered as a closed-loop manufacturing subsystem designed for near-zero emissions, near-zero discharge, and near-zero residual. 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 contingent on execution at commercial scale and validated through SAT and FPT procedures.
2:Facility Redundant Evaporator Architecture
PRE-EVP-001 is configured as a 2:facility redundant pair (PRE-EVP-001A duty / PRE-EVP-001B hot standby). Both units are sized for full facility Liquifact load. SCADA auto-switches on duty unit fault in <30 seconds. No manual intervention required for standby activation.
CBT-PRE-TDS-005 defines engineering requirements for the Pregenesis Liquifact Collection and Evaporation system. This system collects all free-liquid streams generated across Pregenesis operations, buffers them in PRE-LFB-001, and evaporates them in PRE-EVP-001 to produce distilled water for REG-WHSG-001 feedwater supply and a solids concentrate for disposal routing (D-17 open). The system operates continuously and is integral to the Pregenesis closed-loop water balance.
Both PRE-LFB-001 and PRE-EVP-001 are Pregenesis Protocol modules reclassified from Regenesis scope in Session 5 (SCS-20260407-005 §3). Carbotura Inc. holds all design authority. The ASI (vendor pending D-ASI-01) holds no design authority.
All throughput guarantees and performance metrics are baselined to RevCon 3: $150M–$325M/yr revenue floor at 400 TPD baseline factory configuration.
2. Facility Context & Module Boundaries
2.1 Building Location
| Building | PIMB — Pregenesis Integrated Manufacturing Building |
| Zone | Dedicated Liquifact room or alcove — negative pressure, drain-all-to-sump design |
| NXS-Z2 proximity | Must be within NXS-Z2-FLUID routing reach of WHSG thermal supply. D-24 governs cross-zone routing. |
2.2 Module Boundaries
| Module | Tag | Upstream Boundary | Downstream Boundary |
|---|---|---|---|
| Liquifact Collection Buffer | PRE-LFB-001 | Facility-wide drip pan collection manifold (all Pregenesis modules) | PRE-LFB-001 discharge pump → PRE-EVP-001 inlet (D-11 connector) |
| Liquifact Evaporator (duty) | PRE-EVP-001A | PRE-LFB-001 discharge (D-11 connector) | Distillate water → ASI-EVP-H2O → NXS-Z2-FLUID → REG-WHSG-001 feedwater · Solids concentrate → D-17 routing |
| Liquifact Evaporator (standby) | PRE-EVP-001B | PRE-LFB-001 discharge (D-11 connector) | Same as PRE-EVP-001A |
| APS boundary | All modules | All evaporator vapor connections to APS | ASI-APS-FLG at APS capture manifold |
2.3 Liquifact Stream Sources — Complete
| Source | Module | Stream Type | Basis |
|---|---|---|---|
| Trough 1 floor drains and drip pans | Module 0B | Leachate from Manufacturing Feedstock tipping | Continuous drip |
| Trough 2 floor drains | Module 0B | Biosludge/Enhancement Admix leachate | Continuous |
| TISAB/EASB floor drains | Module 0A/0C | Truck drainage and washdown | Periodic |
| Module 0D — LBS drain | Module 0D | Biosludge spillage and line purge | Periodic |
| T2-DCN centrate (centrifuge filtrate) | Module T2 | High-suspended-solids centrate | Continuous in T2 operation |
| T2-ITD condensate | Module T2 | Water vapor condensed from indirect drying | Continuous in T2 operation |
| Shredder Train drip pans | Modules 1–7 | Oil, moisture, incidental liquid from Manufacturing Feedstock | Continuous |
| PRE-EVP-001 condensate return (non-distillate) | PRE-EVP-001 | Evaporator non-condensables and condenser drain | Recirculate to PRE-LFB-001 |
3. Process Description
3.1 Narrative Overview
Liquifact — the collective term for all free-liquid streams generated by Pregenesis operations — drains by gravity and pump conveyance to PRE-LFB-001. The buffer provides surge capacity to decouple collection (variable rate, dependent on truck tipping activity and T2 operation) from evaporation (steady-state continuous).
PRE-EVP-001 (duty unit) draws Liquifact from PRE-LFB-001 and evaporates the water fraction using WHSG High-Temperature Thermal Recovery delivered via NXS-Z2-FLUID. The evaporator is an indirect thermal forced-circulation type: thermal energy from WHSG is transferred through a shell-and-tube or plate heat exchanger — the process Liquifact never contacts the WHSG thermal fluid. Evaporated water is condensed to distilled water and discharged via ASI-EVP-H2O to the NXS-Z2-FLUID return path for REG-WHSG-001 boiler feedwater. The non-evaporated solids concentrate is discharged via the concentrate outlet (D-17 routing — open).
All evaporator vapor that is not condensed is routed to the APS Capture Stream. The evaporator operates under slightly reduced pressure relative to PIMB ambient to ensure all vapor is captured. PRE-EVP-001B is on standby; on PRE-EVP-001A fault, SCADA auto-switches thermal supply and Liquifact feed to PRE-EVP-001B within one valve-switching cycle.
3.2 Process Flow Table
| Step | Module | Action | Output State | Key Parameter |
|---|---|---|---|---|
| 1 | All Pregenesis modules | Liquifact drains to collection manifold | Mixed liquid stream | Gravity drainage — drain-all-to-sump layout |
| 2 | PRE-LFB-001 | Buffer accumulation | Buffered Liquifact | Level monitored — HIGH alarm triggers EVP duty increase |
| 3 | PRE-LFB-001 → PRE-EVP-001 | Transfer pump delivers Liquifact to EVP inlet | Feed stream | D-11 connector — OPEN. Pump: 316L SS, VFD-controlled |
| 4 | PRE-EVP-001 | Indirect thermal evaporation — WHSG thermal via NXS-Z2 | Water vapor + solids concentrate | 200–400°C thermal input parametric (D-THM-01 CLOSED) |
| 5 | PRE-EVP-001 | Condensation of water vapor | Distilled water output | Distillate quality: conductivity ≤50 μS/cm (WHSG feedwater spec) |
| 6 | PRE-EVP-001 → NXS-Z2 | Distilled water discharge via ASI-EVP-H2O | Distillate to WHSG feedwater | Connector: ASI-EVP-H2O — defined (TDS-001 §5.1) |
| 7 | PRE-EVP-001 | Solids concentrate discharge | Concentrated slurry / paste | D-17 routing OPEN — hold in concentrate tank pending resolution |
| 8 | PRE-EVP-001 | Non-condensable vapor → APS | APS Capture Stream | ASI-APS-FLG connection — enclosed, negative pressure |
3.3 Mass Balance (400 TPD Canonical Basis)
| Stream | Flow Rate | Basis |
|---|---|---|
| Total Liquifact input to PRE-LFB-001 | ~60 TPD (~2.5 TPH) | ARM-2026-001 §4 Correction 3 — 15% of 400 TPD input |
| Assumed water fraction (evaporable) | ~50–55 TPD (~90% of Liquifact) | Parametric — Liquifact is predominantly aqueous; solids content variable |
| Distilled water output (to WHSG feedwater) | ~50–55 TPD | Matches evaporable water fraction |
| Solids concentrate output | ~5–10 TPD | Non-evaporable fraction — D-17 routing open |
| WHSG thermal input consumed | ~250–700 kW at 400 TPD duty | Parametric — see §8 Utilities Register |
OPEN — D-17: Solids Concentrate Routing
Solids concentrate routing from PRE-EVP-001 is unresolved. Concentrate hold tank sized for 72-hour surge at maximum concentrate rate pending D-17 decision. Concentrate composition (DS%, heavy metals, organics) must be characterized before routing can be specified.
4. Feedstock Design Envelope
4.1 Liquifact Composition — Design Basis
| Parameter | P50 Value | P90 Value (Design Limit) | Basis |
|---|---|---|---|
| Total solids (TS) | 2–5% | 10% | Parametric — mixed Pregenesis leachate, centrate, condensate. Dominated by T2-DCN centrate composition. |
| Total suspended solids (TSS) | 1–3% | 7% | Same basis |
| pH | 5–8 | 4–9 | Parametric — Manufacturing Feedstock leachate composition-dependent |
| Temperature at PRE-LFB-001 inlet | Ambient–60°C | 80°C | T2-ITD condensate may arrive hot |
| Oil and grease | <500 mg/L | <2,000 mg/L | Shredder Train lubricant drip and Manufacturing Feedstock organic content |
| Chlorides | <500 mg/L | <2,000 mg/L | Manufacturing Feedstock-dependent |
| Conductivity | 1,000–5,000 μS/cm | 10,000 μS/cm | Parametric |
Guarantee Conditionality: All throughput, performance, and availability guarantees apply when Liquifact composition is within the P90 design envelope defined above, utilities are provided at specification, operation follows OPS procedures, Planned Maintenance Intervals are adhered to, and the ASI has completed FAT and issued the Unitized Warranty Passport.
Prohibited Inputs: Bulk solvents or concentrated chemical streams (route to Owner hazardous waste path); pH <3 or >11 (neutralize before routing); Temperature >80°C (route through intermediate cooling); Free oil >2% by volume (skim before routing — oil impairs evaporator heat transfer).
5. Module Equipment Specifications
5.1 PRE-LFB-001 — Liquifact Collection Buffer
| Tag | PRE-LFB-001 |
| Function | Receive, buffer, and homogenize all Pregenesis Liquifact streams prior to evaporation |
| Type | Covered collection sump or vertical cylindrical tank with agitation. Covered to prevent APS pressure interference; agitated to prevent settling. |
| Material | 316L stainless steel — corrosion resistance for mixed-composition acidic/alkaline Liquifact |
| Useful volume (400 TPD basis) | 2–10 m³ — parametric. D-23 (buffer hold time 20–30 min OPEN). At 2.5 TPH = ~0.83–1.25 m³/20–30 min + surge allowance. OER Gate 2 confirmation. |
| Level instrumentation | Continuous ultrasonic level transmitter + HIGH/HIGH alarm → SCADA |
| Transfer pump | 316L SS centrifugal or progressive cavity, VFD-controlled, 1+1 duty/standby |
| Agitator | Low-speed submersible or side-entry mixer. Prevent sludge settling from T2-DCN centrate fraction. |
| Drain-all-to-sump design | Full floor drainage to PRE-LFB-001 collection point — no dead-leg drain paths |
| SCADA integration | ASI-DAT-MOD-TCP — level, pump status, agitator status |
| CAPEX [Class 2 ±15%] | $100K–$400K parametric [2026 USD] — tank + pump + agitator + instrumentation. OER Gate 2 OEM quote. |
5.2 PRE-EVP-001 — Liquifact Evaporator (2× Redundant Pair)
| Tag | PRE-EVP-001A (duty) / PRE-EVP-001B (standby) |
| Function | Evaporate water fraction from Liquifact — produce distilled water for WHSG feedwater and solids concentrate |
| Type | Forced-Circulation Indirect Thermal Evaporator. Thermal input via indirect heat exchanger — WHSG thermal fluid never contacts Liquifact stream. No MVR (conflicts with WHSG thermal-source architecture). |
| Thermal input | WHSG High-Temperature Thermal Recovery 200–400°C via NXS-Z2-FLUID. D-THM-01 CLOSED PARAMETRIC: 10–40 bar steam or thermal oil equivalent. |
| Thermal consumption | 250–700 kW per unit at 400 TPD (50% duty each). Parametric — basis: latent heat of water evaporation (~2,260 kJ/kg) at ~350 kg/hr per unit evaporation duty. OER Gate 2 OEM confirmation. |
| Evaporation capacity | ~30 TPD water per unit (50% duty). At 400 TPD facility, ~50–55 TPD total water to evaporate; each unit handles full load in redundancy mode. |
| Distillate quality | ≤50 μS/cm conductivity — WHSG feedwater specification. Confirmed at FAT. |
| Distillate outlet | ASI-EVP-H2O → NXS-Z2-FLUID → REG-WHSG-001 feedwater. Connector defined TDS-001 §5.1. |
| Concentrate outlet | D-17 open — 72-hr concentrate hold tank included in scope |
| Operating pressure | Slight vacuum (–50 to –200 mbar relative). Ensures vapor flows to condenser and non-condensables to APS; prevents positive-pressure vapor egress. |
| Condenser | Integral — surface condenser, cooling water from NXS-Z2 Zero-E Thermal Recovery |
| APS vapor connection | ASI-APS-FLG — all non-condensable vapor → APS Capture Stream |
| Wetted materials | 316L SS or Duplex 2205 (Ti upgrade available for high-chloride service) |
| Redundancy | 2:facility — one unit on duty, one on hot standby. SCADA auto-switches in <30 sec. |
| Standby switch | Automatic — SCADA detects duty unit fault → opens standby inlet valve, closes duty inlet valve |
| SCADA integration | ASI-DAT-MOD-TCP — level, temperature, pressure, distillate conductivity, concentrate level, thermal input flow |
| CAPEX per unit [Class 2 ±15%] | $600K–$2,000K parametric [2026 USD] — industrial forced-circulation evaporator at ~30 TPD water evaporation duty. OER Gate 2 OEM quote required. |
| CAPEX 2 units | $1,200K–$4,000K parametric |
| CAPEX distillate conductivity monitor | $15K–$30K — inline conductivity, standard instrumentation |
| CAPEX concentrate hold tank (D-17 pending) | $50K–$150K parametric — 72-hr surge capacity |
6. APS Interface Register
APS Process-Capture Basis Statement
CFM figures are process-capture basis only. No dilution air, comfort ventilation, or regulatory dispersion airflow is included. All APS Capture Stream flows represent vapor streams recovered internally. APS CFM values for PRE-EVP-001 require OEM sizing — dependent on evaporator operating pressure, condenser efficiency, and non-condensable load. To be confirmed at OER Gate 2.
| Capture Point | Module | Normal CFM | Peak CFM | Temp at Capture | Material | Connector |
|---|---|---|---|---|---|---|
| PRE-LFB-001 tank vent | PRE-LFB-001 | OPEN — OER Gate 2 | OPEN | Ambient + | Water vapor, volatiles from Liquifact | ASI-APS-FLG |
| PRE-EVP-001A vapor non-condensable vent | PRE-EVP-001A | OPEN — OER Gate 2 | OPEN | 40–80°C (post-condenser) | Water vapor, trace volatiles | ASI-APS-FLG |
| PRE-EVP-001B vapor non-condensable vent | PRE-EVP-001B | OPEN — OER Gate 2 | OPEN | 40–80°C (post-condenser) | Water vapor, trace volatiles | ASI-APS-FLG |
| Concentrate hold tank vent | Concentrate tank | Minimal | Minimal | Ambient | Water vapor, trace organics | ASI-APS-FLG |
7. Modular Installability & ICD
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 Liquifact within the P90 envelope, witnessed by Carbotura Engineering, Owner's Engineer, and an independent third party.
| ICD Reference | Interface | Connection Type | ASI Standard | Test Requirement | Status |
|---|---|---|---|---|---|
| ICD-LFB-COLL-001 | All Pregenesis module drip pans → PRE-LFB-001 | Gravity drain manifold — 316L SS; sealed covers at all drain points | 316L SS flanged gravity drain | SAT: collection manifold slope ≥1% confirmed at all drain points; zero dead-leg paths | DEFINED — Rev 0 |
| ICD-LFB-EVP-001 | PRE-LFB-001 discharge pump → PRE-EVP-001 inlet | ASI-LFB-DRN | ASI-LFB-DRN (D-11 OPEN) | SAT: continuous flow from PRE-LFB-001 to PRE-EVP-001 inlet at design flow rate; pump VFD response to level signal | OPEN — OER Gate 2: D-11 (connector type/size pending OEM) |
| ICD-EVP-DIST-001 | PRE-EVP-001 distillate outlet → NXS-Z2-FLUID → REG-WHSG-001 feedwater | ASI-EVP-H2O | ASI-EVP-H2O | FPT: distillate conductivity ≤50 μS/cm at outlet continuously over 72-hr TPGT; pressure within NXS-Z2 operating range | DEFINED in part — physical standard D-THM-02 OPEN |
| ICD-WHSG-EVP-001 | REG-WHSG-001 via NXS-Z2-FLUID → PRE-EVP-001 heat exchanger | ASI-THM-HT | ASI-THM-HT | FPT: PRE-EVP-001 thermal input at 200–400°C / 10–40 bar; evaporation at rated capacity | OPEN — OER Gate 2: D-THM-02 physical standard |
| ICD-EVP-CONC-001 | PRE-EVP-001 concentrate outlet → concentrate hold tank | Physical flange — 316L SS | 316L SS flange (D-17 routing OPEN) | SAT: concentrate hold tank fill confirmed; no discharge path active until D-17 resolved | OPEN — OER Gate 1: D-17 resolution required |
| ICD-EVP-APS-001 | PRE-EVP-001 vapor vent → APS capture manifold | ASI-APS-FLG | ASI-APS-FLG | SAT: negative pressure confirmed at all PRE-EVP-001 vapor connections; no positive-pressure vapor egress | OPEN — OER Gate 2: APS CFM OEM sizing |
| ICD-LFB-APS-001 | PRE-LFB-001 tank vent → APS capture manifold | ASI-APS-FLG | ASI-APS-FLG | SAT: negative pressure confirmed at PRE-LFB-001 tank vent | OPEN — OER Gate 2: APS CFM OEM sizing |
| ICD-NXS-Z1-LFB-001 | NXS-Z1-ELEC → PRE-LFB-001 (pump, agitator, instrumentation) | ASI-ZBK-MPC (1,500V DC Zone Bus) | ASI-ZBK-MPC | SAT: all PRE-LFB-001 drives and controls energized; SCADA data confirmed | DEFINED — ARM-2026-002 |
| ICD-NXS-Z1-EVP-001 | NXS-Z1-ELEC → PRE-EVP-001 (drives, instrumentation) | ASI-ZBK-MPC (1,500V DC Zone Bus) | ASI-ZBK-MPC | SAT: all PRE-EVP-001 drives and controls energized; SCADA data confirmed | DEFINED — ARM-2026-002 |
8. Utilities Register
All utilities overhead via NEXUS. Zero underfloor routing.
| Zone | Zone ID | Load / Draw | Basis |
|---|---|---|---|
| Zone 1 — Electrical | NXS-Z1-ELEC |
PRE-LFB-001 pump + agitator: ~5–15 kW. PRE-EVP-001 ×2: circulating pump + instrumentation ~10–30 kW each. Total electrical: ~25–75 kW at 400 TPD basis. | Parametric — OER Gate 2 OEM confirmation |
| Zone 2 — Fluid | NXS-Z2-FLUID |
Thermal input: 250–700 kW per unit (duty unit only at 50% facility load). Total at 400 TPD: 250–700 kW. Distillate return: ~50–55 TPD distilled water to WHSG feedwater (per §3.3). Cooling water to EVP integral condenser via NXS-Z2 Zero-E Thermal Recovery loop. | D-THM-01 parametric closed (200–400°C / 10–40 bar). D-35 energy balance includes this draw. |
| Zone 3 — Gas | NXS-Z3-GAS |
N&sub2; blanket on concentrate hold tank (if volatile contents justify). Compressed air for instrumentation. Parametric — confirm at OER Gate 2. | Parametric |
| Zone 4 — Material | NXS-Z4-MAT |
APS ductwork — non-condensable vapor capture from PRE-LFB-001 and PRE-EVP-001. Ductwork sizing OPEN — OER Gate 2 APS OEM. | OPEN |
9. Vendor Matrix
All procurement subject to American Manufacturing Preference Policy per ARM-2026-002 Cluster H. China, India, Russia, ITAR/BIS/OFAC restricted: direct procurement prohibited. Non-prohibited foreign equipment acceptable via US-domiciled ASI wrapper.
| Equipment | Vendor / OEM | Country | Procurement Path | OEM Guarantee | Lead Time (wks) | CAPEX |
|---|---|---|---|---|---|---|
| Forced-Circulation Evaporator | Swenson Technology (SSEC) | USA — Harvey, IL | Direct — US Manufacturer | Yes — performance | 20–28 | See §5.2 |
| Forced-Circulation Evaporator (alt) | SPX FLOW / APV | USA — Delavan, WI | Direct — US Manufacturer | Yes — performance | 20–28 | See §5.2 |
| Forced-Circulation Evaporator (alt) | GEA Group | Germany | ASI-Integrated (pending D-ASI-01) | Yes — performance | 24–32 | See §5.2 |
| Collection Buffer Tank — PRE-LFB-001 | HOLLOWAY AMERICA | USA — Springfield, MO | Direct — US Manufacturer | Yes — structural | 12–16 | See §5.1 |
| Collection Buffer Tank (alt) | Paul Mueller Company | USA — Springfield, MO | Direct — US Manufacturer | Yes — structural | 10–14 | See §5.1 |
| Transfer Pumps (PRE-LFB-001) | Netzsch (Moyno alternative) | Germany / USA | ASI-Integrated or Direct | Yes | 8–12 | Included in PRE-LFB-001 CAPEX |
| Agitator | Philadelphia Mixing Solutions | USA | Direct — US Manufacturer | Yes | 8–12 | Included in PRE-LFB-001 CAPEX |
| Conductivity Analyzer (distillate) | Mettler Toledo (Thornton) | USA / Switzerland | Direct or ASI-Integrated | Yes — accuracy | 6–10 | $15K–$30K |
OPEN — D-ASI-01: ASI Vendor Not Selected
Procurement path for non-US equipment (GEA Group) remains ASI-Integrated pending D-ASI-01. All US-manufacturer options (Swenson, SPX FLOW, Holloway, Mueller, Philadelphia Mixing) are available as direct procurement regardless of D-ASI-01 status. Recommend issuing RFQ to Swenson Technology and SPX FLOW immediately to establish lead time and CAPEX for OER Gate 2.
10. CAPEX Estimate
All values: Class 2 (±15%) [2026 USD]. Wide range driven primarily by PRE-EVP-001 unit size uncertainty pending D-11 and D-23 resolution and OEM RFQ. Range narrows significantly at OER Gate 2 after Swenson/SPX FLOW RFQ received.
| Line Item | Low ($K) | High ($K) | Basis |
|---|---|---|---|
| PRE-LFB-001 — buffer tank, pump, agitator, instrumentation | 100 | 400 | Parametric — 316L SS tank 2–10 m³ + pump pair + agitator |
| PRE-EVP-001A — forced-circulation evaporator, condenser, controls | 600 | 2,000 | Parametric — industrial evaporator ~30 TPD water duty |
| PRE-EVP-001B — forced-circulation evaporator, condenser, controls | 600 | 2,000 | Same basis — standby unit |
| Concentrate hold tank (D-17 pending) | 50 | 150 | Parametric — 316L SS tank, 72-hr capacity |
| Distillate conductivity monitoring system | 15 | 30 | Standard inline conductivity + SCADA |
| Collection manifold — drain piping, drain pans (Pregenesis-wide) | 100 | 300 | Parametric — 316L SS drain piping facility-wide |
| NEXUS connection — NXS-Z2 thermal supply tie-in | 50 | 150 | Parametric — D-24 routing governs scope |
| ASI packaging, skid fabrication, FAT | 150 | 400 | Parametric — 15–20% of equipment cost |
| Equipment Subtotal | 1,665 | 5,430 | |
| E&I (+15%) | 250 | 815 | |
| Assembly at site (+10%) | 165 | 543 | |
| Contingency (Class 2 — embedded in ±15% band) | Embedded | ||
| TOTAL CAPEX — PRE-TDS-005 Scope | ~$2,080K | ~$6,788K | Class 2 ±15% [2026 USD] |
11. TIC WBS Reconciliation
PRE-TDS-005 scope is included in the master Pregenesis TIC WBS items 1.4 (PRE-LFB-001) and 1.5 (PRE-EVP-001) per CBT-PRE-TDS-001 §11. CAPEX from this document populates those WBS lines.
| WBS | Scope | Low ($K) | High ($K) |
|---|---|---|---|
| 1.4 | PRE-LFB-001 — Liquifact Collection Buffer (complete system) | 400 | 850 |
| 1.5 | PRE-EVP-001 ×2 — Liquifact Evaporators + distillate monitoring + concentrate tank | 1,265 | 4,580 |
| 1.4–1.5 | Collection manifold (facility-wide drain piping to PRE-LFB-001) | 100 | 300 |
| PRE-TDS-005 TIC Contribution | ~$1,765K | ~$5,730K | |
Included: All PRE-LFB-001 and PRE-EVP-001 equipment, ASI packaging and FAT, first-fill spares. Excluded: PIMB structural works; NXS-Z2 primary header (NXS scope); WHSG and REG-WHSG-001 (Regenesis scope).
12. Lead Time Schedule
| Item | Lead Time | Priority | Notes |
|---|---|---|---|
| D-ASI-01 — ASI Vendor Selection | OPEN | Critical | Gate 0 for all ASI-path procurement |
| D-11 — LFB→EVP connector specification | OPEN | Critical | Must be resolved before EVP RFQ can close |
| PRE-EVP-001 ×2 (Swenson / SPX FLOW) | 20–28 weeks | Critical path | Longest lead item in this TDS scope. RFQ recommended immediately. |
| PRE-LFB-001 buffer tank (Holloway / Mueller) | 10–16 weeks | Medium | Can follow EVP order without schedule impact |
| Collection manifold drain piping (316L SS) | 8–12 weeks | Medium | Standard industrial piping |
| Transfer pumps (Netzsch PC or centrifugal) | 8–12 weeks | Medium | Standard lead |
| Conductivity analyzer (Mettler Thornton) | 6–10 weeks | Low | Short lead — order with EVP |
| ASI skid fabrication + FAT (all modules) | 8–16 weeks post equipment receipt | Medium | After EVP and LFB delivered to ASI facility |
Critical path: D-11 resolution → EVP RFQ issue → EVP order → EVP FAT → site delivery → SAT
13. TRL / ERL / IRL Assessment
| Module / Subsystem | TRL | ERL | IRL | Assessment Notes |
|---|---|---|---|---|
| PRE-LFB-001 — Collection Buffer | 9 | 7 | 5 | Tank + pump is fully proven industrial technology TRL=9. ERL=7 at Class 2 stage. IRL=5 — drain manifold routing and collection points defined; D-11 connector open. |
| PRE-EVP-001 — Forced-Circulation Evaporator | 8–9 | 6 | 4 | Industrial evaporator technology TRL=8–9. Specific Liquifact feedstock composition adds novelty (mixed leachate/centrate/condensate) — ERL=6. IRL=4 — D-11 open; D-THM-02 open; D-17 open; D-24 open. |
| Distillate return to WHSG feedwater | 8 | 6 | 5 | Industrial distillate return well-proven. IRL=5 — connector ASI-EVP-H2O defined in TDS-001; physical standard D-THM-02 open. |
| Collection manifold (Pregenesis-wide drain system) | 9 | 6 | 4 | Standard drain piping. IRL limited by undefined routing to PRE-LFB-001 in each module's detailed layout. |
14. Confidence Factor
| Factor | Weight | Score (0–10) | Weighted Score | Basis |
|---|---|---|---|---|
| Technology maturity (TRL) | 25% | 8/10 | 20.0% | Industrial evaporator TRL=9; specific Liquifact feedstock application TRL=7–8 |
| Engineering completeness (ERL) | 20% | 5/10 | 10.0% | Class 2 Rev 0; multiple OPEN ICDs (D-11, D-17, D-23, D-24, D-THM-02) limit score |
| Integration readiness (IRL) | 15% | 4/10 | 6.0% | IRL=4 for EVP — four open ICD items. IRL will improve significantly when D-11, D-17, D-23 resolved. |
| Vendor availability | 15% | 8/10 | 12.0% | Multiple qualified US vendors available for evaporator (Swenson, SPX FLOW) and buffer tank |
| Operational heritage | 15% | 7/10 | 10.5% | Industrial forced-circulation evaporation is well-established; mixed Liquifact feedstock in ACM context is novel |
| Regulatory / permitting | 10% | 7/10 | 7.0% | Closed-loop evaporation with distillate return — near-zero discharge design. Permitting risk low. |
| BASE SCORE | 100% | — | 65.5% | — |
| ADJUSTED (OEM guarantee uplift + ASI) | — | — | 73% — ACCEPTABLE CONFIDENCE | Recovers to ACCEPTABLE CONFIDENCE. Target: re-score to 80%+ at OER Gate 2 after D-11, D-17, D-23, D-THM-02 resolved and OEM RFQ received. |
73% — ACCEPTABLE CONFIDENCE. Proceed with RFQ stage. Primary improvement path: resolve D-11 and D-23, obtain Swenson/SPX FLOW RFQ, close D-17 with a routing decision.
15. Availability Model
Guarantee Conditionality
All throughput, performance, and availability guarantees apply when: (1) Liquifact is within the P90 design envelope in §4; (2) utilities are provided at specification per §8 including WHSG High-Temperature Thermal at specification; (3) operation follows OPS procedures; (4) Planned Maintenance Intervals are adhered to; and (5) the ASI has completed FAT and issued the Unitized Warranty Passport.
| Equipment / Subsystem | MA (%) | MTBF (hrs) | MTTR (hrs) | Source / Basis |
|---|---|---|---|---|
| PRE-LFB-001 — collection buffer (passive tank + pump) | 98–99 | 8,760 (tank); 3,000–5,000 (pumps) | 2–6 | Parametric — standard 316L SS tank and centrifugal/PC pump industrial reference |
| PRE-EVP-001 — forced-circulation evaporator (each unit) | 95–97 | 3,000–6,000 | 8–16 | Industrial evaporator reference (GEA, SPX FLOW operating data — biosolids and leachate service). Parametric pending OEM data. |
| PRE-EVP-001 — System OA (2:facility redundant pair) | 97–99 | N/A | N/A | N+1 redundancy — both units sized for full facility load. Auto-switch in <30 sec on duty fault. |
| Distillate conductivity monitoring | 99 | High | 2 | Standard inline sensor — manual backup (grab sample) available |
| PRE-TDS-005 MODULE SYSTEM OA | 97–99 | — | — | Governed by PRE-EVP-001 system OA. PRE-LFB-001 provides additional surge decoupling — short PRE-EVP-001 outages absorbed in buffer. |
External dependency: PRE-EVP-001 availability is contingent on WHSG High-Temperature Thermal supply at specification via NXS-Z2. If WHSG thermal is unavailable, PRE-EVP-001 cannot operate. PRE-LFB-001 buffer provides hold time (D-23 — 20–30 min parametric) before WHSG feedwater supply to Regenesis is affected.
16. Risk Register
R-01 HIGH — D-11 Open: PRE-LFB-001 → PRE-EVP-001 Connector Not Defined (Integration/ICD)
The physical connector and piping specification between PRE-LFB-001 discharge and PRE-EVP-001 inlet is open (D-11). This prevents the PRE-EVP-001 OEM from confirming inlet nozzle size, which in turn holds the skid design. Until D-11 closes, the EVP RFQ cannot be fully specified.Mitigation: (1) Resolve D-11 in Session 8 — likely a 3–6-in. flanged 316L SS connection based on ~2.5 TPH flow at 400 TPD; (2) Issue EVP RFQ with D-11 as an Architect-to-confirm item, specifying nozzle envelope range 3–8 in.; (3) PRE-LFB-001 and PRE-EVP-001 skids designed with adjustable inlet nozzle position within ±300 mm to accommodate routing flexibility.
R-02 HIGH — WHSG Thermal Supply Dependency (Integration/ICD)
PRE-EVP-001 is entirely dependent on WHSG High-Temperature Thermal Recovery via NXS-Z2. If WHSG thermal is reduced, PRE-EVP-001 evaporation capacity is reduced and PRE-LFB-001 buffer will fill. If buffer overflows, WHSG feedwater supply to Regenesis degrades. This creates a process interdependency between Pregenesis water balance and Regenesis operation.Mitigation: (1) D-35 parametric closed — WHSG thermal budget includes 2–8 MW for PRE-EVP-001 + T2-ITD combined; PRE-EVP-001 draw (~250–700 kW) is a minor fraction; (2) Specify PRE-EVP-001 with 30% thermal turndown capability; (3) If WHSG budget is tight at OER Gate 2, specify supplemental Zero-E Thermal Recovery Stream pre-heating coil as fallback.
R-03 MEDIUM — D-17 Open: Solids Concentrate Routing (Process/Regulatory)
PRE-EVP-001 solids concentrate routing is unresolved (D-17). Concentrate composition is unknown until facility operation characterization. Regulatory classification of concentrate depends on composition — affects disposal permitting.Mitigation: (1) Include 72-hr concentrate hold tank in PRE-EVP-001 skid scope; (2) Characterize Liquifact composition at SAT using representative Manufacturing Feedstock samples; (3) Design concentrate outlet for three routing options: (a) solids dewatering + landfill, (b) return to Trough 2 for T2 processing, (c) direct discharge with treatment — keep all three technically feasible in the piping layout.
R-04 MEDIUM — Liquifact Composition Variability (Process/Performance)
Liquifact composition varies significantly based on Manufacturing Feedstock type, T2-DCN centrate DS%, and tipping floor activity. High-chloride or high-oil Liquifact degrades evaporator heat transfer surfaces.Mitigation: (1) PRE-LFB-001 agitator mandatory — continuous mixing prevents settling and composition spikes reaching EVP; (2) Specify PRE-EVP-001 with Ti heat exchange surfaces as upgrade option for high-chloride service — evaluate at RFQ; (3) Inline oil and conductivity monitoring at PRE-LFB-001 outlet — high readings trigger SCADA alarm before EVP fouling occurs.
R-05 LOW — D-23 Buffer Hold Time (Process/Operations)
PRE-LFB-001 buffer hold time (20 or 30 min — D-23 open) determines how long the system can sustain WHSG feedwater supply to Regenesis during an EVP fault.Mitigation: (1) Resolve D-23 in TDS-005 production review — 30-min hold is recommended; (2) OPS-001 §6.4 captures this dependency — Regenesis Operations is notified immediately on dual EVP fault; (3) Size PRE-LFB-001 for 30-min hold as the conservative basis; add 50% safety factor in tank sizing.
17. Spares Register
| Crit. | Equipment / Item | Qty First Fill | Qty Operating | Notes |
|---|---|---|---|---|
| A | PRE-EVP-001 heat exchanger tube bundle (per unit) | 1 spare bundle | Per degradation | Fouling is primary wear mode; bundle replacement major maintenance event. 16–24 wk lead — stock at commissioning. |
| A | PRE-LFB-001 transfer pump rotor/stator (PC pump) or impeller (centrifugal) | 1 set per pump | 1 set/yr | Critical — pump failure halts EVP feed |
| A | Inline conductivity sensor for distillate monitoring | 2 sensors | 1/yr | Replace on drift outside ±5% — calibration check monthly |
| B | PRE-EVP-001 circulating pump mechanical seal (per unit) | 2 sets | 1 set/yr | High-cycle rotating equipment in aggressive Liquifact service |
| B | PRE-LFB-001 agitator mechanical seal and bearing set | 1 set | Per failure | Submersible or side-entry — confirm seal type at OEM selection |
| B | PRE-EVP-001 valve body + actuator (concentrate outlet) | 1 valve assembly | Per failure | High-solids slurry service — accelerated wear |
| C | Drain manifold collection pan gasket sets (facility-wide) | 1 set | 1 set/2 yr | Replace on pressure-differential or visual degradation |
| C | Concentrate hold tank level sensor | 1 sensor | Per failure | Short lead — standard item |
18. Warranty Register
| Equipment | Warranty Period | OEM Guarantee | Coverage / Notes |
|---|---|---|---|
| PRE-LFB-001 — Collection Buffer (tank + pump + agitator, complete station) | 18 months | Yes — ASI | All LFB equipment as assembled system. Sub-warranties pass through Unitized Warranty Passport. Pump wear excluded after 6 months. |
| PRE-EVP-001 ×2 — Forced-Circulation Evaporators | 18–24 months | Yes — OEM (Swenson / SPX FLOW preferred) | Parts and labor. Thermal performance guarantee (distillate conductivity ≤50 μS/cm) contingent on Liquifact within P90 design envelope AND WHSG thermal supply at spec per ICD-WHSG-EVP-001. Heat exchanger fouling excluded after 12 months of continuous operation. |
| Concentrate Hold Tank | 18 months | Yes — OEM | Structural and leak-free. Wear surfaces excluded after 6 months in high-DS% service. |
| Distillate Conductivity Monitoring System | 18 months | Yes — OEM (Mettler Toledo) | Accuracy guarantee ±2% full-scale. Electrode wear excluded after 12 months. |
| Collection Manifold Drain Piping (facility-wide) | 18 months | Yes — ASI | All 316L SS collection piping assembled and leak-tested by ASI. |
18.1 Warranty Administration
The ASI (vendor to be selected per D-ASI-01) is the single point of warranty contact for all sub-tier OEM suppliers contracted under ASI scope for the Liquifact system. The Unitized Warranty Passport issued at FAT covers PRE-LFB-001 and PRE-EVP-001 as integrated modules. Carbotura Engineering maintains the warranty log per ISO 9001:2015 Clause 8.7.
Note: PRE-EVP-001 thermal performance warranty is conditional on WHSG supply at specification per ICD-WHSG-EVP-001. The ICD defines the thermal supply boundary condition. If WHSG supply deviates from specification, the PRE-EVP-001 performance warranty exclusions apply at that interface.
END OF DOCUMENT — CBT-PRE-TDS-005 | Rev 0 | April 2026 | CONFIDENTIAL — CARBOTURA INC.
2:Facility Redundant Evaporator | ARM-2026-002 Incorporated | WHSG 200–400°C | D-THM-01 CLOSED PARAMETRIC | RevCon 3 Baseline
2:Facility Redundant Evaporator | ARM-2026-002 Incorporated | WHSG 200–400°C | D-THM-01 CLOSED PARAMETRIC | RevCon 3 Baseline