Regenesis Protocol — Master Architecture
Master Integration Document — All 24 Regenesis Modules — 400 TPD / 32 MW / 16 Recyclotrons
| Document Number | CBT-REG-TDS-001 |
| Revision | Rev 0 — April 8, 2026 |
| Status | WORKING DOCUMENT — Pre-Release Engineering Development |
| OER Classification | Class 2 Target (±15%) — Not yet released for PE sign-off |
| Governing ARMs | ARM-2026-001 | ARM-2026-002 |
| Revenue Baseline | RevCon 3 — $150M–$325M/yr at 400 TPD |
| ASI | RK Industries — Authorized Strategic Integrator (D-ASI-01 pending) |
| Classification | ISC-2 Confidential |
1. Executive Summary
2. Facility Context and Module Boundaries
2.1 Building Architecture
| Parameter | Value |
|---|---|
| Regenesis Manufacturing Building (RMB) | Dedicated structure — all 24 Regenesis Protocol modules; separate from PIMB |
| PIMB→RMB interface | Recyclotron Feed Header (RFH) penetration at shared building wall — ASI-RFH-FLG (12-in. ANSI 150# RF flange) |
| PIMB→RMB thermal interface | NEXUS Zone 2 (NXS-Z2-FLUID) cross-zone routing — WHSG High-Temperature Thermal header from REG-WHSG-001 to PRE-EVP-001 and T2-ITD in PIMB |
| RMB nameplate capacity | 1,000 TPD as-received — scaling by 100 TPD module replication |
| Canonical engineering baseline | 400 TPD — 4 trains × 4 reactors = 16 Recyclotrons |
| Heavy mobile equipment in RMB | ZERO — all material transfers by NEXUS Z4 pneumatics, drag chain conveyors, and closed conveying systems |
| NEXUS architecture | Four-zone overhead — NXS-Z1-ELEC / NXS-Z2-FLUID / NXS-Z3-GAS / NXS-Z4-MAT — zero underfloor routing |
| RMB footprint | OPEN — OER Gate 2 RMB layout pending after Tier 2 replication factor confirmation |
2.2 Upstream and Downstream Boundaries
| Boundary | From | To | Interface | Status |
|---|---|---|---|---|
| Upstream — feedstock in | Pregenesis Protocol (PIMB) | REG-FDS-001 | ASI-RFH-FLG (12-in. ANSI 150# RF) | DEFINED — ECN-004 |
| Downstream — H2 out | REG-BSH-001 | Zero-E PowerBlock | ASI-H2-HPS | OPEN — D-29, D-H2-01 |
| Downstream — carbon out | REG-CCS-001 | Regenesis MAX — Carbon Line | Conveyor transfer | OPEN — OER Gate 2 |
| Downstream — oil out | REG-BSO-001 | Regenesis MAX — Oil Line | Pipe flange (spec TBD) | OPEN — OER Gate 2 |
| Downstream — water out | REG-BSW-001 | Regenesis MAX — Water Line | Pipe flange (spec TBD) | OPEN — OER Gate 2 |
| Downstream — metal out | REG-MET-001 | Regenesis MAX — Metal Line | Conveyor/container | OPEN — OER Gate 2 |
| Downstream — glass out | REG-GLS-001 | Regenesis MAX — Glass Line | Conveyor/container | OPEN — OER Gate 2 |
| Downstream — mineral out | REG-MIN-001 | Regenesis MAX — Mineral Line | Conveyor/container | OPEN — OER Gate 2 |
| Downstream — CO2 out | REG-BSC2-001 | Sequestration or mineral carbonation | Pipe (disposition TBD) | OPEN — OER Gate 2 |
| Thermal out — cross-protocol | REG-WHSG-001 | NXS-Z2 → PRE-EVP-001 + T2-ITD (PIMB) | ASI-THM-HT | OPEN — D-THM-01 |
| Power in | Zero-E PowerBlock | All RMB module positions | ASI-PBK-QC / ASI-ZBK-MPC / ASI-MVDC-HPR | DEFINED — ARM-2026-002 |
| Data — SCADA | All modules | Central control | ASI-DAT-MOD-TCP | DEFINED |
3. Module Register
Tier 1 — ×16 per 400 TPD (1 per Recyclotron)
| Tag | Module | Function |
|---|---|---|
| REG-FDS-001 | Recyclotron Feed Distribution System | Receives blended feedstock from RFH; meters and distributes to Recyclotron injection system; lock hopper pressure equalization |
| REG-MCR-001 | Recyclotron Reactor | Microwave Catalytic Reforming (MCR) vessel; produces OmniCrude RC0 across all 8 phases |
| REG-ADX-001 | Enhancement Admix Dosing Exchange | Receives Enhancement Admix from REG-EAS-001; doses at EAF = 25% into feedstock stream upstream of injection nozzles |
Tier 2 — ×8 per 400 TPD (2 parallel trains per 4-reactor group)
| Tag | Module | Function |
|---|---|---|
| REG-PCY-001 | Primary Cyclone | First-stage inertial separation of carbon fines from hot gas exit stream; carbon catch → REG-CCS-001 |
| REG-CSC-001 | Carbon Recovery Syngas Cracker | High-temperature thermal cracking (1,300–1,800°C) of residual tars; produces clean syngas and additional carbon catch |
| REG-SCY-001 | Secondary Cyclone | Second-stage carbon fines separation post-CSC; carbon catch → REG-CCS-001 |
| REG-WHSG-001 | Waste Heat Steam Generator | Recovers high-temperature thermal energy from post-CSC syngas; produces steam/thermal oil for NXS-Z2 |
| REG-CDN-001 | Condenser | Cools syngas below aromatic condensate dew point; collects condensate for OWS |
| REG-OWS-001 | Oil/Water Separator | Separates aromatic condensate from process water fraction; routes each to buffer storage |
| REG-WGS-001 | Water Gas Shift Reactor | CO + H2O → CO2 + H2; increases H2 concentration in product gas stream |
| REG-GPU-001 | Gas Processing Unit (PSA/Membrane) | Separates product gas into H2, N2, CO2, and CO streams; each routed to dedicated buffer storage |
| REG-BSC-001 | CO Recirculation Buffer | 15–30 minute hold buffer for CO before re-injection to REG-WGS-001 |
Tier 3 — ×1 per facility
| Tag | Module | Destination |
|---|---|---|
| REG-BSH-001 | Hydrogen Buffer Storage | Zero-E PowerBlock via ASI-H2-HPS |
| REG-BSN-001 | Nitrogen Buffer Storage | NXS-Z3-GAS for injection system recycle |
| REG-BSC2-001 | CO2 Buffer Storage | Sequestration or mineral carbonation (disposition OER Gate 2) |
| REG-BSO-001 | Aromatic Condensate Buffer Storage | Regenesis MAX — Oil Line |
| REG-BSW-001 | Process Water Buffer Storage | Regenesis MAX — Water Line |
| REG-CCS-001 | Carbon Conveyance System | Regenesis MAX — Carbon Line |
| REG-EAS-001 | Enhancement Admix Storage & Metering | REG-ADX-001 via NXS-Z4-MAT |
| REG-MET-001 | Metal Phase Recovery | Regenesis MAX — Metal Line |
| REG-GLS-001 | Glass Phase Separation | Regenesis MAX — Glass Line |
| REG-MIN-001 | Mineral Phase Collection | Regenesis MAX — Mineral Line |
| REG-SLD-001 | Solids Discharge — Primary | Receives reactor bed bottom discharge; transfers to REG-SLD-002 |
| REG-SLD-002 | Solids Discharge — Secondary | Buffer and transfer to MET/GLS/MIN separation train |
4. Process Description
4.1 MCR Process
The Regenesis Protocol executes Microwave Catalytic Reforming (MCR) — the canonical Carbotura process name for the Recyclotron reactor chemistry. MCR is not pyrolysis. MCR is not gasification. MCR is a proprietary co-processing regime in which Manufacturing Feedstock and Enhancement Admix undergo simultaneous microwave irradiation, catalytic reaction, and thermal conversion within a single vessel under controlled nitrogen atmosphere.
The Enhancement Admix particles — which carry residual carbon and metallic compounds — are highly efficient microwave susceptors at 915 MHz. They absorb microwave energy and convert it to thermal energy, creating microscopic thermal gradients throughout the feedstock/admix mixture. This is the mechanism of Flash Reformation: rapid molecular devolatilization driven by microwave-induced thermal energy delivery from within the mixture, not from external combustion or heated walls.
Gas extraction: Product gas exits through the top dome vortex finder and is routed to the downstream train (REG-PCY-001). All gas extraction is under vacuum — the 0.5 atm operating pressure ensures net inflow of N2 at any seal leakage point, never outflow of process gas to atmosphere.
Solid discharge: The bed discharges continuously through the double-stage rotary airlock at the vessel bottom. The solid discharge is a mixture of OmniCrude Metal Phase, Glass Phase, and Mineral Phase — separated downstream by REG-MET-001, REG-GLS-001, and REG-MIN-001.
4.2 Mass Balance — 400 TPD
| Stream | Source / Destination | Mass Flow (TPD) | % MCR Feed | Notes |
|---|---|---|---|---|
| Input Streams | ||||
| Manufacturing Feedstock (SMU solid) | Pregenesis RFH | 300 | 75% | Blended, shredded — per Pregenesis mass balance |
| Enhancement Admix | REG-EAS-001 | 100 | 25% | EAF = 25% — microwave susceptor + in-situ catalyst |
| Total MCR feed | 400 | 100% | Input to REG-MCR-001 | |
| Output Streams | ||||
| Gas Phase (syngas — H2, CO, CO2, CH4) | REG-GPU-001 → separation | 124.5 | 31.1% | H2 ~20 TPD est. to Zero-E PowerBlock |
| OmniCrude Aromatic Condensate | REG-BSO-001 → MAX Oil Line | 51 | 12.8% | |
| OmniCrude Process Water Phase | REG-BSW-001 → MAX Water Line | 62.25 | 15.6% | |
| OmniCrude Carbon Phase (Solid) | REG-CCS-001 → MAX Carbon Line | 62.25 | 15.6% | |
| Metal + Glass + Mineral Phases | REG-MET/GLS/MIN-001 | ~100 | ~25% | OPEN — D-35 phase split TBD |
4.3 Key Process Parameters
| Parameter | Value | Status |
|---|---|---|
| MCR feed rate per reactor | 25 TPD | LOCKED |
| Applied microwave power per reactor | 600 kW | LOCKED |
| Magnetron frequency | 915 MHz | LOCKED |
| Magnetron count per reactor | 6 × 100 kW / WR-975 | LOCKED |
| AC draw per reactor (magnetrons) | 720 kW | LOCKED |
| Vessel operating pressure | 0.5 atm vacuum | LOCKED |
| Vessel operating temperature — nominal | 550°C | LOCKED |
| Vessel operating temperature — maximum | 650°C | LOCKED |
| Vessel internal atmosphere | N2 — continuous purge | LOCKED |
| CSC operating temperature | 1,300–1,800°C | LOCKED |
| EAF (Enhancement Admix-to-Feed Ratio) | 25% | LOCKED |
| Injection architecture | N2 dense-phase pneumatic — Si3N4 nozzles | LOCKED — D-31 closed |
| Injection N2 SLR | — | OPEN — D-46 |
| WHSG thermal output (steam/oil) | 200–400°C range | OPEN — D-THM-01 |
5. Interface Control
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.
| ICD Reference | Interface Description | Connection Type | ASI Standard | Test Requirement | Status |
|---|---|---|---|---|---|
| ICD-RFH-FDS-001 | Recyclotron Feed Header — blended feedstock from PIMB to REG-FDS-001 | Flanged pipe — 12-in. ANSI 150# RF | ASI-RFH-FLG | FAT: pressure test; SAT: 72-hr throughput | DEFINED — ECN-004 |
| ICD-FDS-MCR-001 | FDS to Recyclotron injection — N2 dense-phase pneumatic — Si3N4 nozzles | N2 pneumatic injection nozzle | OPEN — OER Gate 2 | FAT: injection flow verification | OPEN — D-48, D-50 |
| ICD-MCR-PCY-001 | Recyclotron top dome gas exit to Primary Cyclone | High-temp flanged pipe — Inconel 625 | OPEN — OER Gate 2 | FAT: vacuum integrity | OPEN — OER Gate 2 |
| ICD-MCR-SLD-001 | Recyclotron bottom discharge — rotary airlock to SLD-001 | Flanged rotary airlock — Inconel 625 | OPEN — OER Gate 2 | FAT: airlock cycle test | OPEN — OER Gate 2 |
| ICD-WHSG-NXS-Z2-001 | WHSG thermal output to NXS-Z2 cross-protocol header | Steam/thermal oil flanged — 200–400°C | ASI-THM-HT | FAT: steam pressure; SAT: thermal output | OPEN — D-THM-01 |
| ICD-GPU-BSH-001 | GPU H2 product stream to BSH-001 buffer | High-pressure H2 pipe | ASI-H2-HPS | FAT: pressure test; SAT: H2 purity | OPEN — D-29, D-H2-01 |
| ICD-PWR-MCR-001 | Zero-E PowerBlock to magnetron inverter skid | 800V DC — <3m — HVIL integrated | ASI-PBK-QC (Amphenol ePower-Lite) | FAT: HVIL break test; SAT: full-load | DEFINED — ARM-2026-002 |
| ICD-PWR-ZBK-001 | 1,500V DC Zone Bus to RMB | Liquid-cooled laminated busbar | ASI-ZBK-MPC (Staubli MPC MULTILAM) | FAT: continuity; SAT: full-zone load | DEFINED — ARM-2026-002 |
| ICD-DAT-MCR-001 | SCADA data interface — all process variables per reactor | Modbus TCP/IP — M12 | ASI-DAT-MOD-TCP | FAT: all tags live; SAT: alarm response | DEFINED |
6. Availability Model
| Scenario | Downstream Trains Active | Facility Throughput | Governing Redundancy | Notes |
|---|---|---|---|---|
| Normal operation | 8 of 8 | 400 TPD (100%) | N/A — full capacity | 4 groups × 2 trains at 50% duty each |
| 1 train in planned maintenance | 7 of 8 | 400 TPD (100%) | Tier 1 — in-group 1-of-2 | Sister train absorbs full group load |
| Up to 4 trains offline (one per group) | 4 of 8 | 400 TPD (100%) | Tier 1 — in-group 1-of-2 | Maximum simultaneous maintenance with zero throughput loss |
| 1 full train pair (both in one group) offline | 6 of 8 | 300 TPD (75%) | Tier 2 — cross-train failover | One reactor group fully offline |
| 2 full train pairs offline | 4 of 8 | 200 TPD (50%) | Minimum Factory Module equivalent |
7. Utilities Load Schedule
NXS-Z1-ELEC — Electrical
| Load | Equipment | Per Unit | Qty | Total (400 TPD) | Notes |
|---|---|---|---|---|---|
| Magnetron AC draw | REG-MCR-001 magnetrons | 720 kW | 16 | 11,520 kW (11.52 MW) | 36% of 32 MW Zero-E PowerBlock |
| DC/AC inverter losses | 750 kW skid per reactor | ~30 kW | 16 | ~480 kW | Inverter efficiency ~96% |
| Revolving airlock drives | REG-SLD + FDS actuators | ~5–15 kW | Multiple | <200 kW est. | OPEN — OER Gate 2 |
| CSC heating (if electric) | REG-CSC-001 | OPEN — D-65 | 8 | OPEN | Blocks NXS-Z1 final load schedule |
| GPU compressors | REG-GPU-001 | OPEN | 8 | OPEN | OEM sizing required |
| Controls & instrumentation | All modules | ~10 kW | 24 | ~240 kW | 48V DC controls bus |
| Total electrical (partial) | ≥11.52 MW | CSC and GPU loads open |
8. CAPEX
| WBS | Line Item | Qty (400 TPD) | Status |
|---|---|---|---|
| R-01 | REG-MCR-001 Recyclotron Reactor skid (vessel + magnetrons + inverter + airlock) | 16 | OPEN — OER Gate 2 |
| R-02 | REG-FDS-001 Feed Distribution System | 16 | OPEN — OER Gate 2 |
| R-03 | REG-ADX-001 Enhancement Admix Dosing | 16 | OPEN — OER Gate 2 |
| R-04 | REG-PCY-001 Primary Cyclone | 8 | OPEN — OER Gate 2 |
| R-05 | REG-CSC-001 Carbon Recovery Syngas Cracker | 8 | OPEN — OER Gate 2 |
| R-06 | REG-SCY-001 Secondary Cyclone | 8 | OPEN — OER Gate 2 |
| R-07 | REG-WHSG-001 Waste Heat Steam Generator | 8 | OPEN — OER Gate 2 |
| R-08 | REG-CDN-001 Condenser | 8 | OPEN — OER Gate 2 |
| R-09 | REG-OWS-001 Oil/Water Separator | 8 | OPEN — OER Gate 2 |
| R-10 | REG-WGS-001 Water Gas Shift Reactor | 8 | OPEN — OER Gate 2 |
| R-11 | REG-GPU-001 Gas Processing Unit | 8 | OPEN — OER Gate 2 |
| R-12 | REG-BSC-001 CO Recirculation Buffer | 8 | OPEN — OER Gate 2 |
| R-13 | Tier 3 buffer storage (BSH, BSN, BSC2, BSO, BSW) | 1 each | OPEN — OER Gate 2 |
| R-14 | REG-CCS-001 Carbon Conveyance | 1 | OPEN — OER Gate 2 |
| R-15 | REG-EAS-001 Enhancement Admix Storage | 1 | OPEN — OER Gate 2 |
| R-16 | REG-MET/GLS/MIN-001 Phase Separation Train | 1 | OPEN — OER Gate 2 |
| R-17 | REG-SLD-001/002 Solids Discharge System | 1 | OPEN — OER Gate 2 |
| TOTAL MODULE CAPEX | OPEN — OER Gate 2 Class 4 Placeholder, 2026 USD |
9. Risk Register
| Risk ID | Category | Description | Severity | Mitigation 1 | Mitigation 2 |
|---|---|---|---|---|---|
| R-01 | Process | MCR energy balance (D-35) closes unfavorably — 600 kW insufficient for 25 TPD per reactor | HIGH | D-37 conservative no-admix basis; EAF admix thermal boost (D-39) | Recyclotron Gen 1 cartridge-replaceable per D-40 — Gen 2 can use higher-power magnetrons |
| R-02 | Process | N2 injection SLR (D-46) too high — NXS-Z3 undersized; GPU N2 recovery insufficient | HIGH | GPU PSA scalable — N2 recovery uprated after conveying test | Single Starved Screw (D-31 Rank 2) as contingency injection if pneumatic N2 load prohibitive |
| R-03 | Procurement | Recyclotron vessel (Inconel 625 first article) lead time >78 weeks | HIGH | Engage Haynes International and Special Metals at OER Gate 2 for long-lead procurement | Multi-source Inconel 625 plate/bar; backup fabricator under ASI |
| R-04 | Safety | H2 accumulation in RMB from GPU/BSH-001/injection leak | HIGH | HVIL fail-closed on ASI-H2-HPS; catalytic bead H2 detection throughout RMB; auto N2 purge on H2 alarm | PEM consumes H2 locally; RMB H2 inventory limited to buffer only |
| R-05 | Process | CSC thermal input (D-65) — achieving 1,300–1,800°C from 650°C requires significant energy | HIGH | D-65 critical path; Option A (dedicated 915 MHz microwave) preferred — architecturally consistent | Option D (controlled partial oxidation) if dedicated power prohibitive — requires feasibility study |
| R-06 | Integration | WHSG thermal output (D-THM-01) insufficient for T2-ITD + PRE-EVP-001 | MEDIUM | D-THM-01 scope expanded to size WHSG for combined load | Supplemental Zero-E Thermal Recovery heating (85–95°C) available if needed |
| R-07 | Procurement | Si3N4 AM component sourcing — D-58 open; no confirmed US AM vendor | MEDIUM | American Manufacturing Preference — ASI-Integrated path for non-prohibited foreign vendor | Engage Synergen Metal, Ceramatec, or Coherent as US Si3N4 AM candidates |
10. Open Decisions
| D-# | Description | Priority | Blocks |
|---|---|---|---|
| D-31 | ✅ CLOSED Session 6 — N2 Dense-Phase Pneumatic, Si3N4 nozzles selected | — | Unblocks CBT-REG-TDS-001 Rev 0 and CBT-RCT-IDS-001 injection section |
| D-65 (NEW) | CSC thermal input source — how is REG-CSC-001 heated to 1,300–1,800°C from 650°C syngas inlet | 🔴 CRITICAL PATH | CSC equipment spec; energy balance (D-35); NXS-Z1 load |
| D-35 | MCR energy balance — 25 TPD / 600 kW — now includes D-65 scope | 🔴 | Magnetron count confirmation; CAPEX |
| D-29 | REG-BSH-001 H2 buffer sizing and pressure | 🔴 | Zero-E H2 distribution |
| D-46 | N2-to-feedstock SLR — conveying test required | 🔴 | NXS-Z3 sizing; GPU N2 load |
| D-THM-01 | WHSG steam parameters — T2-ITD + PRE-EVP-001 combined load | 🔴 | LCI RFQ; WHSG sizing |
| D-48 | Nozzle ID sizing — requires D-55 (particle size) first | 🟡 | Nozzle fabrication; CBT-RCT-IDS-001 |
| D-55 | Max particle size from Pregenesis shredder | 🔴 | Nozzle ID (D-48); SiC screw gap |
11. Confidence Factor
Consistent with Class 4-to-Class 2 transition document at Rev 0
| Domain | Weight | Score (1–5) | Weighted Score | Assessment Basis |
|---|---|---|---|---|
| Process chemistry (MCR) | 25% | 3 | 0.75 | TRL 5–6; D-35 energy balance open |
| Vessel design completeness | 20% | 3 | 0.60 | All geometry locked; IDS in progress; D-32, D-56 open |
| Injection system | 10% | 4 | 0.40 | D-31 closed this session; D-46–D-52 are sizing details |
| Downstream gas train | 15% | 4 | 0.60 | Standard equipment; OEM selection OER Gate 2 |
| Mass and energy balance closure | 15% | 2 | 0.30 | D-35 open; D-46, D-THM-01 open |
| CAPEX readiness | 10% | 1 | 0.10 | Class 4 placeholder; no OEM quotes |
| Interface control completeness | 5% | 2 | 0.10 | Multiple ASI connector standards pending |
| TOTAL | 100% | 2.85 |