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Regenesis Protocol — Technical Design Specification

Regenesis Protocol — Master Architecture

Master Integration Document — All 24 Regenesis Modules — 400 TPD / 32 MW / 16 Recyclotrons

Doc No.CBT-REG-TDS-001
RevisionRev 0
StatusWORKING DOCUMENT
OER ClassClass 2 Target — Not Yet Released
ClassificationISC-2 Confidential
RevCon BaselineRevCon 3 — $150M–$325M/yr at 400 TPD
Document Control
Document NumberCBT-REG-TDS-001
RevisionRev 0 — April 8, 2026
StatusWORKING DOCUMENT — Pre-Release Engineering Development
OER ClassificationClass 2 Target (±15%) — Not yet released for PE sign-off
Governing ARMsARM-2026-001 | ARM-2026-002
Revenue BaselineRevCon 3 — $150M–$325M/yr at 400 TPD
ASIRK Industries — Authorized Strategic Integrator (D-ASI-01 pending)
ClassificationISC-2 Confidential
⚠️ WORKING DOCUMENT
This document is in pre-release engineering development. Values marked OPEN are unresolved at this revision. Not released for PE sign-off. Class 2 (±15%) target at Rev 1 following OER Gate 2 data gathering.

1. Executive Summary

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 Statement
The Regenesis Protocol is engineered as a closed-loop manufacturing subsystem designed for near-zero emissions, near-zero discharge, and near-zero residual. This design intent is achieved through: continuous negative-pressure operation of the Recyclotron vessel at 0.5 atm vacuum; nitrogen-atmosphere enclosure eliminating all combustion pathways; continuous gas extraction through the vortex finder to the APS Capture Stream and product gas train; double-stage N2-purged rotary airlock solid discharge; and the absence of any routine wastewater discharge or atmospheric release pathway. Environmental performance outcomes are contingent on execution at commercial scale and will be validated through SAT and Full Performance Testing (FPT) procedures.
OER Classification Statement
This document represents Class 2 (±15%) OEM Engineering Release (OER), equivalent to "Front-End Engineering Design (FEED) / DOE FEL-3" [external regulatory reference — DOE LPO / AACE 18R-97 only]. This classification is the required pre-condition for DOE Loan Programs Office Title 17 loan guarantee applications, PE sign-off, and institutional project finance close. Where open decisions prevent Class 2 closure of specific parameters, those parameters are explicitly flagged as OPEN with the gate at which they close.
ASI Role Statement
Carbotura Inc. holds all design authority, engineering specifications, and OEM intellectual property. The Authorized Strategic Integrator (ASI) — RK Industries, with formal designation pending D-ASI-01 — is responsible for packaging design, system integration, fabrication, factory assembly, Factory Acceptance Testing (FAT), quality assurance, third-party certifications, Unitized Warranty Passport issuance, and authorized spares provisioning, all executed to Carbotura OEM specification. The ASI holds no design authority. All engineering changes require Carbotura Engineering Change Notice (ECN) authorization prior to ASI implementation.
Domestic Manufacturing Commitment Statement
All Carbotura Advanced Circular Manufacturing (ACM) Facility modules are assembled, tested, and warranted in the United States of America by the Authorized Strategic Integrator (ASI). Equipment procurement adheres to Carbotura's American Manufacturing Preference Policy. This commitment supports DOE Loan Programs Office domestic content requirements, Buy American Act alignment, and institutional investor supply chain transparency obligations.
Revenue Performance Baseline Statement
All throughput guarantees and performance metrics in this document are baselined to RevCon 3: $150M–$325M/yr revenue floor at 400 TPD baseline factory configuration (128 PEM modules / 32 MW Zero-E PowerBlock / 16 Recyclotrons at 4 trains × 4 reactors / one Pregenesis Protocol module at full nameplate throughput).

2. Facility Context and Module Boundaries

2.1 Building Architecture

ParameterValue
Regenesis Manufacturing Building (RMB)Dedicated structure — all 24 Regenesis Protocol modules; separate from PIMB
PIMB→RMB interfaceRecyclotron Feed Header (RFH) penetration at shared building wall — ASI-RFH-FLG (12-in. ANSI 150# RF flange)
PIMB→RMB thermal interfaceNEXUS 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 capacity1,000 TPD as-received — scaling by 100 TPD module replication
Canonical engineering baseline400 TPD — 4 trains × 4 reactors = 16 Recyclotrons
Heavy mobile equipment in RMBZERO — all material transfers by NEXUS Z4 pneumatics, drag chain conveyors, and closed conveying systems
NEXUS architectureFour-zone overhead — NXS-Z1-ELEC / NXS-Z2-FLUID / NXS-Z3-GAS / NXS-Z4-MAT — zero underfloor routing
RMB footprintOPEN — OER Gate 2 RMB layout pending after Tier 2 replication factor confirmation

2.2 Upstream and Downstream Boundaries

BoundaryFromToInterfaceStatus
Upstream — feedstock inPregenesis Protocol (PIMB)REG-FDS-001ASI-RFH-FLG (12-in. ANSI 150# RF)DEFINED — ECN-004
Downstream — H2 outREG-BSH-001Zero-E PowerBlockASI-H2-HPSOPEN — D-29, D-H2-01
Downstream — carbon outREG-CCS-001Regenesis MAX — Carbon LineConveyor transferOPEN — OER Gate 2
Downstream — oil outREG-BSO-001Regenesis MAX — Oil LinePipe flange (spec TBD)OPEN — OER Gate 2
Downstream — water outREG-BSW-001Regenesis MAX — Water LinePipe flange (spec TBD)OPEN — OER Gate 2
Downstream — metal outREG-MET-001Regenesis MAX — Metal LineConveyor/containerOPEN — OER Gate 2
Downstream — glass outREG-GLS-001Regenesis MAX — Glass LineConveyor/containerOPEN — OER Gate 2
Downstream — mineral outREG-MIN-001Regenesis MAX — Mineral LineConveyor/containerOPEN — OER Gate 2
Downstream — CO2 outREG-BSC2-001Sequestration or mineral carbonationPipe (disposition TBD)OPEN — OER Gate 2
Thermal out — cross-protocolREG-WHSG-001NXS-Z2 → PRE-EVP-001 + T2-ITD (PIMB)ASI-THM-HTOPEN — D-THM-01
Power inZero-E PowerBlockAll RMB module positionsASI-PBK-QC / ASI-ZBK-MPC / ASI-MVDC-HPRDEFINED — ARM-2026-002
Data — SCADAAll modulesCentral controlASI-DAT-MOD-TCPDEFINED

3. Module Register

Train Architecture (LOCKED)
16 Recyclotrons organized into 4 reactor-groups of 4 reactors each. Each reactor-group is served by 2 parallel downstream trains, each sized for the full group load (100 TPD). Normal duty per train: 50%. One train offline → sister train absorbs full load → zero facility throughput reduction. This is a 1-of-2 redundant architecture within each group.
24 Regenesis Modules across 3 Tiers

Tier 1 — ×16 per 400 TPD (1 per Recyclotron)

TagModuleFunction
REG-FDS-001Recyclotron Feed Distribution SystemReceives blended feedstock from RFH; meters and distributes to Recyclotron injection system; lock hopper pressure equalization
REG-MCR-001Recyclotron ReactorMicrowave Catalytic Reforming (MCR) vessel; produces OmniCrude RC0 across all 8 phases
REG-ADX-001Enhancement Admix Dosing ExchangeReceives 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)

TagModuleFunction
REG-PCY-001Primary CycloneFirst-stage inertial separation of carbon fines from hot gas exit stream; carbon catch → REG-CCS-001
REG-CSC-001Carbon Recovery Syngas CrackerHigh-temperature thermal cracking (1,300–1,800°C) of residual tars; produces clean syngas and additional carbon catch
REG-SCY-001Secondary CycloneSecond-stage carbon fines separation post-CSC; carbon catch → REG-CCS-001
REG-WHSG-001Waste Heat Steam GeneratorRecovers high-temperature thermal energy from post-CSC syngas; produces steam/thermal oil for NXS-Z2
REG-CDN-001CondenserCools syngas below aromatic condensate dew point; collects condensate for OWS
REG-OWS-001Oil/Water SeparatorSeparates aromatic condensate from process water fraction; routes each to buffer storage
REG-WGS-001Water Gas Shift ReactorCO + H2O → CO2 + H2; increases H2 concentration in product gas stream
REG-GPU-001Gas Processing Unit (PSA/Membrane)Separates product gas into H2, N2, CO2, and CO streams; each routed to dedicated buffer storage
REG-BSC-001CO Recirculation Buffer15–30 minute hold buffer for CO before re-injection to REG-WGS-001

Tier 3 — ×1 per facility

TagModuleDestination
REG-BSH-001Hydrogen Buffer StorageZero-E PowerBlock via ASI-H2-HPS
REG-BSN-001Nitrogen Buffer StorageNXS-Z3-GAS for injection system recycle
REG-BSC2-001CO2 Buffer StorageSequestration or mineral carbonation (disposition OER Gate 2)
REG-BSO-001Aromatic Condensate Buffer StorageRegenesis MAX — Oil Line
REG-BSW-001Process Water Buffer StorageRegenesis MAX — Water Line
REG-CCS-001Carbon Conveyance SystemRegenesis MAX — Carbon Line
REG-EAS-001Enhancement Admix Storage & MeteringREG-ADX-001 via NXS-Z4-MAT
REG-MET-001Metal Phase RecoveryRegenesis MAX — Metal Line
REG-GLS-001Glass Phase SeparationRegenesis MAX — Glass Line
REG-MIN-001Mineral Phase CollectionRegenesis MAX — Mineral Line
REG-SLD-001Solids Discharge — PrimaryReceives reactor bed bottom discharge; transfers to REG-SLD-002
REG-SLD-002Solids Discharge — SecondaryBuffer 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

StreamSource / DestinationMass Flow (TPD)% MCR FeedNotes
Input Streams
Manufacturing Feedstock (SMU solid)Pregenesis RFH30075%Blended, shredded — per Pregenesis mass balance
Enhancement AdmixREG-EAS-00110025%EAF = 25% — microwave susceptor + in-situ catalyst
Total MCR feed400100%Input to REG-MCR-001
Output Streams
Gas Phase (syngas — H2, CO, CO2, CH4)REG-GPU-001 → separation124.531.1%H2 ~20 TPD est. to Zero-E PowerBlock
OmniCrude Aromatic CondensateREG-BSO-001 → MAX Oil Line5112.8%
OmniCrude Process Water PhaseREG-BSW-001 → MAX Water Line62.2515.6%
OmniCrude Carbon Phase (Solid)REG-CCS-001 → MAX Carbon Line62.2515.6%
Metal + Glass + Mineral PhasesREG-MET/GLS/MIN-001~100~25%OPEN — D-35 phase split TBD
D-35 Open Items for Mass Balance Closure
H2 fraction of syngas by TPD (requires energy balance); CO/CO2/CH4 split within 124.5 TPD syngas; Enhancement Admix Metal/Glass/Mineral phase split (composition-dependent); N2 balance (D-46 and D-47 dependent).

4.3 Key Process Parameters

ParameterValueStatus
MCR feed rate per reactor25 TPDLOCKED
Applied microwave power per reactor600 kWLOCKED
Magnetron frequency915 MHzLOCKED
Magnetron count per reactor6 × 100 kW / WR-975LOCKED
AC draw per reactor (magnetrons)720 kWLOCKED
Vessel operating pressure0.5 atm vacuumLOCKED
Vessel operating temperature — nominal550°CLOCKED
Vessel operating temperature — maximum650°CLOCKED
Vessel internal atmosphereN2 — continuous purgeLOCKED
CSC operating temperature1,300–1,800°CLOCKED
EAF (Enhancement Admix-to-Feed Ratio)25%LOCKED
Injection architectureN2 dense-phase pneumatic — Si3N4 nozzlesLOCKED — D-31 closed
Injection N2 SLROPEN — D-46
WHSG thermal output (steam/oil)200–400°C rangeOPEN — 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 ReferenceInterface DescriptionConnection TypeASI StandardTest RequirementStatus
ICD-RFH-FDS-001Recyclotron Feed Header — blended feedstock from PIMB to REG-FDS-001Flanged pipe — 12-in. ANSI 150# RFASI-RFH-FLGFAT: pressure test; SAT: 72-hr throughputDEFINED — ECN-004
ICD-FDS-MCR-001FDS to Recyclotron injection — N2 dense-phase pneumatic — Si3N4 nozzlesN2 pneumatic injection nozzleOPEN — OER Gate 2FAT: injection flow verificationOPEN — D-48, D-50
ICD-MCR-PCY-001Recyclotron top dome gas exit to Primary CycloneHigh-temp flanged pipe — Inconel 625OPEN — OER Gate 2FAT: vacuum integrityOPEN — OER Gate 2
ICD-MCR-SLD-001Recyclotron bottom discharge — rotary airlock to SLD-001Flanged rotary airlock — Inconel 625OPEN — OER Gate 2FAT: airlock cycle testOPEN — OER Gate 2
ICD-WHSG-NXS-Z2-001WHSG thermal output to NXS-Z2 cross-protocol headerSteam/thermal oil flanged — 200–400°CASI-THM-HTFAT: steam pressure; SAT: thermal outputOPEN — D-THM-01
ICD-GPU-BSH-001GPU H2 product stream to BSH-001 bufferHigh-pressure H2 pipeASI-H2-HPSFAT: pressure test; SAT: H2 purityOPEN — D-29, D-H2-01
ICD-PWR-MCR-001Zero-E PowerBlock to magnetron inverter skid800V DC — <3m — HVIL integratedASI-PBK-QC (Amphenol ePower-Lite)FAT: HVIL break test; SAT: full-loadDEFINED — ARM-2026-002
ICD-PWR-ZBK-0011,500V DC Zone Bus to RMBLiquid-cooled laminated busbarASI-ZBK-MPC (Staubli MPC MULTILAM)FAT: continuity; SAT: full-zone loadDEFINED — ARM-2026-002
ICD-DAT-MCR-001SCADA data interface — all process variables per reactorModbus TCP/IP — M12ASI-DAT-MOD-TCPFAT: all tags live; SAT: alarm responseDEFINED

6. Availability Model

In-Group 1-of-2 Redundancy
Up to 4 downstream trains can be simultaneously offline — one per group — with zero facility throughput impact.
ScenarioDownstream Trains ActiveFacility ThroughputGoverning RedundancyNotes
Normal operation8 of 8400 TPD (100%)N/A — full capacity4 groups × 2 trains at 50% duty each
1 train in planned maintenance7 of 8400 TPD (100%)Tier 1 — in-group 1-of-2Sister train absorbs full group load
Up to 4 trains offline (one per group)4 of 8400 TPD (100%)Tier 1 — in-group 1-of-2Maximum simultaneous maintenance with zero throughput loss
1 full train pair (both in one group) offline6 of 8300 TPD (75%)Tier 2 — cross-train failoverOne reactor group fully offline
2 full train pairs offline4 of 8200 TPD (50%)Minimum Factory Module equivalent

7. Utilities Load Schedule

NXS-Z1-ELEC — Electrical

LoadEquipmentPer UnitQtyTotal (400 TPD)Notes
Magnetron AC drawREG-MCR-001 magnetrons720 kW1611,520 kW (11.52 MW)36% of 32 MW Zero-E PowerBlock
DC/AC inverter losses750 kW skid per reactor~30 kW16~480 kWInverter efficiency ~96%
Revolving airlock drivesREG-SLD + FDS actuators~5–15 kWMultiple<200 kW est.OPEN — OER Gate 2
CSC heating (if electric)REG-CSC-001OPEN — D-658OPENBlocks NXS-Z1 final load schedule
GPU compressorsREG-GPU-001OPEN8OPENOEM sizing required
Controls & instrumentationAll modules~10 kW24~240 kW48V DC controls bus
Total electrical (partial)≥11.52 MWCSC and GPU loads open
🔴 D-65 OPEN — CRITICAL PATH
CSC thermal input source undefined at Rev 0. Blocks CSC equipment specification and NXS-Z1 final load schedule. Resolution required before Rev 1.

8. CAPEX

Class 4 Order-of-Magnitude Placeholder (−30% to +50%)
All line items require OEM quotes at OER Gate 2 before Class 2 (±15%) accuracy can be achieved. No CAPEX figures are given at this revision.
WBSLine ItemQty (400 TPD)Status
R-01REG-MCR-001 Recyclotron Reactor skid (vessel + magnetrons + inverter + airlock)16OPEN — OER Gate 2
R-02REG-FDS-001 Feed Distribution System16OPEN — OER Gate 2
R-03REG-ADX-001 Enhancement Admix Dosing16OPEN — OER Gate 2
R-04REG-PCY-001 Primary Cyclone8OPEN — OER Gate 2
R-05REG-CSC-001 Carbon Recovery Syngas Cracker8OPEN — OER Gate 2
R-06REG-SCY-001 Secondary Cyclone8OPEN — OER Gate 2
R-07REG-WHSG-001 Waste Heat Steam Generator8OPEN — OER Gate 2
R-08REG-CDN-001 Condenser8OPEN — OER Gate 2
R-09REG-OWS-001 Oil/Water Separator8OPEN — OER Gate 2
R-10REG-WGS-001 Water Gas Shift Reactor8OPEN — OER Gate 2
R-11REG-GPU-001 Gas Processing Unit8OPEN — OER Gate 2
R-12REG-BSC-001 CO Recirculation Buffer8OPEN — OER Gate 2
R-13Tier 3 buffer storage (BSH, BSN, BSC2, BSO, BSW)1 eachOPEN — OER Gate 2
R-14REG-CCS-001 Carbon Conveyance1OPEN — OER Gate 2
R-15REG-EAS-001 Enhancement Admix Storage1OPEN — OER Gate 2
R-16REG-MET/GLS/MIN-001 Phase Separation Train1OPEN — OER Gate 2
R-17REG-SLD-001/002 Solids Discharge System1OPEN — OER Gate 2
TOTAL MODULE CAPEXOPEN — OER Gate 2 Class 4 Placeholder, 2026 USD

9. Risk Register

Risk IDCategoryDescriptionSeverityMitigation 1Mitigation 2
R-01ProcessMCR energy balance (D-35) closes unfavorably — 600 kW insufficient for 25 TPD per reactorHIGHD-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-02ProcessN2 injection SLR (D-46) too high — NXS-Z3 undersized; GPU N2 recovery insufficientHIGHGPU PSA scalable — N2 recovery uprated after conveying testSingle Starved Screw (D-31 Rank 2) as contingency injection if pneumatic N2 load prohibitive
R-03ProcurementRecyclotron vessel (Inconel 625 first article) lead time >78 weeksHIGHEngage Haynes International and Special Metals at OER Gate 2 for long-lead procurementMulti-source Inconel 625 plate/bar; backup fabricator under ASI
R-04SafetyH2 accumulation in RMB from GPU/BSH-001/injection leakHIGHHVIL fail-closed on ASI-H2-HPS; catalytic bead H2 detection throughout RMB; auto N2 purge on H2 alarmPEM consumes H2 locally; RMB H2 inventory limited to buffer only
R-05ProcessCSC thermal input (D-65) — achieving 1,300–1,800°C from 650°C requires significant energyHIGHD-65 critical path; Option A (dedicated 915 MHz microwave) preferred — architecturally consistentOption D (controlled partial oxidation) if dedicated power prohibitive — requires feasibility study
R-06IntegrationWHSG thermal output (D-THM-01) insufficient for T2-ITD + PRE-EVP-001MEDIUMD-THM-01 scope expanded to size WHSG for combined loadSupplemental Zero-E Thermal Recovery heating (85–95°C) available if needed
R-07ProcurementSi3N4 AM component sourcing — D-58 open; no confirmed US AM vendorMEDIUMAmerican Manufacturing Preference — ASI-Integrated path for non-prohibited foreign vendorEngage Synergen Metal, Ceramatec, or Coherent as US Si3N4 AM candidates

10. Open Decisions

D-#DescriptionPriorityBlocks
D-31✅ CLOSED Session 6 — N2 Dense-Phase Pneumatic, Si3N4 nozzles selectedUnblocks 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 PATHCSC equipment spec; energy balance (D-35); NXS-Z1 load
D-35MCR energy balance — 25 TPD / 600 kW — now includes D-65 scope🔴Magnetron count confirmation; CAPEX
D-29REG-BSH-001 H2 buffer sizing and pressure🔴Zero-E H2 distribution
D-46N2-to-feedstock SLR — conveying test required🔴NXS-Z3 sizing; GPU N2 load
D-THM-01WHSG steam parameters — T2-ITD + PRE-EVP-001 combined load🔴LCI RFQ; WHSG sizing
D-48Nozzle ID sizing — requires D-55 (particle size) first🟡Nozzle fabrication; CBT-RCT-IDS-001
D-55Max particle size from Pregenesis shredder🔴Nozzle ID (D-48); SiC screw gap

11. Confidence Factor

Confidence Factor: 2.85 / 5.00
Consistent with Class 4-to-Class 2 transition document at Rev 0
DomainWeightScore (1–5)Weighted ScoreAssessment Basis
Process chemistry (MCR)25%30.75TRL 5–6; D-35 energy balance open
Vessel design completeness20%30.60All geometry locked; IDS in progress; D-32, D-56 open
Injection system10%40.40D-31 closed this session; D-46–D-52 are sizing details
Downstream gas train15%40.60Standard equipment; OEM selection OER Gate 2
Mass and energy balance closure15%20.30D-35 open; D-46, D-THM-01 open
CAPEX readiness10%10.10Class 4 placeholder; no OEM quotes
Interface control completeness5%20.10Multiple ASI connector standards pending
TOTAL100%2.85
CBT-REG-TDS-001 Rev 0  |  WORKING DOCUMENT — Pre-Release Engineering Development  |  ISC-2 Confidential  |  April 8, 2026