§0 — SPV Summary
§0.1 — KPI Strip (Phase Initial — 100 TPD)
Phase Initial
Option B
ESTIMATED
ESTIMATED
ESTIMATED
Coverage Ratio
ESTIMATED
ESTIMATED
§0.2 — Entity Overview
| Parameter | Value |
|---|---|
| Entity name | Carbotura Alabama SPV LLC (proposed) — wholly owned Carbotura subsidiary |
| Facility specification | Advanced Circular Manufacturing (ACM) — Microwave Catalytic Reforming (MCR) · Anoxic, sub-atmospheric · 100 TPD Phase Initial → 400 TPD Expanded |
| Feedstock | Automotive Shredder Residue (ASR) / Auto Fluff — DJJ SE shredder network + Nucor mill-adjacent operations |
| COA term | 30 years from Phase Initial COD |
| TMC Fee | $150.00/ton (agreed · Carbotura ceiling) · 2.5%/yr escalator |
| Project model | Build-Own-Operate (BOO) · Carbotura owns and operates facility · zero counterparty capital obligation |
| Accounting standard | US GAAP — counterparty is US-domiciled (Nucor Corporation, NYSE: NUE) · SPV structured as US LLC |
| Asset base treatment | Option B — Full Institutional (PP&E + COA Reserve NI 43-101 gross LOM NRV + IP License NPV) |
| Capital structure | Equity 20% / Grant 15% / Senior Debt 65% · Conservative 15% grant scenario · Interpretation A equity |
| Total project cost — Initial | $75,000,000 (Phase Initial · 1 module · 100 TPD) |
| Total project cost — Expanded | $247,500,000 (4 modules · 400 TPD) |
| Annual throughput — Initial | 36,500 tpy (100 TPD × 365 days) |
| Annual throughput — Expanded | 146,000 tpy (400 TPD × 365 days) |
| RevCon baseline | $150/ton TMC Fee (agreed) + commodity outputs (synthetic graphite, hydrogen, recovered metals — ESTIMATED) |
§1 — Sources and Uses
§1.1 — Total Project Uses
| Use | Phase Initial (100 TPD) | Incremental Phases 2–4 | Total Expanded | Notes |
|---|---|---|---|---|
| ACM process equipment — MCR modules | $52,500,000 | $120,750,000 | $173,250,000 | 70% of first module; 70% of increment modules |
| Site development, civil & utilities | $12,000,000 | $21,000,000 | $33,000,000 | Site prep, roads, drainage, power connection |
| Engineering, procurement & construction management | $7,500,000 | $22,500,000 | $30,000,000 | EPC management, commissioning |
| Contingency (5%) | $3,000,000 | $8,250,000 | $11,250,000 | 5% of hard costs |
| Total Project Cost | $75,000,000 | $172,500,000 | $247,500,000 | Carbotura standard CapEx parameters |
§1.2 — Sources of Funds — Phase Initial (Three-Tranche Structure)
| Tranche | Provider | Amount | % | Terms | Source Type |
|---|---|---|---|---|---|
| Local SPV Equity (Interpretation A) | Institutional Partner / Carbotura | $15,000,000 | 20% | Equity — pro-rata dividend rights post debt service | CONFIRMED |
| Grant / Concessional Finance | Federal / State programs (IRA §45X, ADECA) | $11,250,000 | 15% | Non-repayable — Conservative 15% scenario | ESTIMATED |
| Senior Secured Project Debt | Infrastructure lender(s) — indicative 6.5% / 25yr | $48,750,000 | 65% | Senior secured · 6.5% · 25yr · P+I amortising | ESTIMATED |
| Total Sources | $75,000,000 | 100% | Funding gap: $0 | ||
§1.3 — Capital Stack Waterfall
§2 — Opening Balance Sheet (Option B — Full Institutional) · Phase Initial
The COA Reserve is recognized on the balance sheet using the NI 43-101 gross Life-of-Mine Net Realisable Value (LOM NRV) basis — the contracted feedstock revenue stream over the 30-year COA term, analogous to a Proven Reserve statement for extractive industries. This basis supports collateral valuation and reserve reporting. The DCF NPV basis (economic present value at 8% discount rate) provides the economic equity value figure used in the returns analysis in §5. Both bases are valid and serve distinct institutional purposes.
§2.1 — Assets
| Asset Category | Component | Amount (US$) | Basis |
|---|---|---|---|
| Non-Current Assets — Tangible (PP&E) | ACM process equipment, civil & utilities (gross) | $72,000,000 | Cost — construction cost |
| Engineering, procurement & EPC management | $7,500,000 | Cost — capitalised | |
| Less: Contingency reserve (held) | ($3,000,000) | Reserve | |
| Subtotal PP&E (Net) | $76,500,000 | US GAAP ASC 360 | |
| Non-Current Assets — Intangible (Option B) | COA Reserve — Intangible Asset (NI 43-101 gross LOM NRV: $150 × 36,500 tpy × 30yr) |
$164,250,000 | Gross LOM NRV — contracted revenue stream |
| IP License Value (Relief-from-Royalty NPV) | $45,000,000 | ESTIMATED Pending term sheet | |
| Environmental Attributes (memo only — not in base) | TBD | IRA §45V/§45Q/§45X — upside contingent on NAICS classification | |
| Subtotal Intangible Assets | $209,250,000 | US GAAP ASC 350 | |
| Current Assets | Cash & equivalents (funded at close) | $0 | Fully deployed to PP&E at close |
| TOTAL ASSET BASE | $285,750,000 | Option B — Full Institutional basis | |
| Memo: Total Base incl. Environmental Attributes (upside — not on balance sheet) | +TBD | Contingent on IRA manufacturing NAICS confirmation | |
§2.2 — Liabilities and Funding at Close
| L&E Category | Component | Amount (US$) |
|---|---|---|
| Long-Term Liabilities | Senior Secured Debt — Phase Initial (6.5%, 25yr) | $48,750,000 |
| Grant / Concessional Finance (non-repayable) | $11,250,000 | |
| Total Liabilities | $60,000,000 | |
| Equity | Paid-In Cash Equity — Local Institutional Partner (20%) | $15,000,000 |
| Contributed IP & COA Rights — Carbotura (balance) | $210,750,000 | |
| Total Equity | $225,750,000 | |
| TOTAL FUNDED PROJECT (L + E) | $285,750,000 | |
§2.3 — Asset Coverage Summary
| Metric | Numerator | Denominator | Ratio | Assessment |
|---|---|---|---|---|
| Tangible Asset Coverage | PP&E $76.5M | Project Cost $75M | 1.02× | Full tangible coverage of project cost |
| COA Reserve / Total Debt | $164.25M | $48.75M | 3.37× | Strong reserve coverage of senior debt |
| Full Asset Base / Project Cost | $285.75M | $75M | 3.81× | Institutional-grade asset/cost ratio |
| DCF Equity Value / Equity Invested | ~$62M (ESTIMATED) | $15M | ~4.1× | Strong equity upside position at financial close |
Executive Implications — Balance Sheet
- The $164.25M COA Reserve is the primary asset: a 30-year contracted revenue stream at $150/ton TMC Fee, recognized on a gross LOM NRV basis consistent with NI 43-101 Proven Reserve methodology. At 3.37× senior debt, it provides institutional-grade lender collateral without reliance on commodity market assumptions.
- Option B Full Institutional recognition maximises the asset base visible to lenders and co-investors. The $285.75M total asset base against $75M project cost produces a 3.81× coverage ratio — comfortably within infrastructure lender thresholds.
- The Environmental Attributes line (IRA §45V/§45Q/§45X) is memo-only: not on the balance sheet, but represents material upside contingent on manufacturing NAICS classification confirmation from the EPA RCRA Exclusion Petition.
§3 — Capital Structure Visualisation
§3.1 — Asset Base vs. Capital Raised
Chart: Capital Raised vs. Asset Stack — Phase Initial (100 TPD / $75M) · Insight: Capital raised ($75M) is dwarfed by the total asset base ($285.75M) — COA Reserve is the primary institutional asset. · Source: Registry §M · April 2026 · ESTIMATED
§3.2 — Asset Stack Composition
| Asset Layer | Value ($M) | % of Total | Basis |
|---|---|---|---|
| PP&E — ACM Plant (net) | $76.5M | 26.8% | Cost — US GAAP ASC 360 — CONFIRMED |
| COA Reserve — Intangible | $164.25M | 57.5% | NI 43-101 Gross LOM NRV — $150 × 36,500 × 30 — DERIVED |
| IP License Value | $45.0M | 15.7% | Relief-from-Royalty NPV — ESTIMATED |
| Total Asset Base | $285.75M | 100% | US GAAP ASC 360/350 — Option B |
§3.3 — COA Reserve as Primary Asset
The COA Reserve is recognized as an intangible asset representing the net present value of contracted feedstock processing rights over the 30-year COA term. The NI 43-101 gross LOM NRV basis ($164.25M) is calculated as: TMC Fee × Annual Throughput × COA Term = $150 × 36,500 tpy × 30 years. This is the Proven Reserve equivalent for a contracted materials processing facility — the contracted counterparty obligation provides certainty analogous to a mining reserve statement. Two legitimate bases exist: (1) NI 43-101 gross NRV — for collateral and reserve reporting; (2) DCF NPV — for economic present value and equity returns analysis. The balance sheet uses basis (1); §5 returns analysis uses basis (2).
§4 — Debt Schedule (Phase Initial)
§4.1 — Debt Tranche Summary (Grant-Adjusted)
| Tranche | Borrowing | Rate | Term | Annual P+I | Debt-Free By |
|---|---|---|---|---|---|
| Senior Secured — Phase Initial (65% of $75M) | $48,750,000 | 6.5% | 25 years | ~$3,900,000 | Year 26 |
| Grant / Concessional (non-repayable) | $11,250,000 | 0% | Non-repayable | $0 | N/A |
| Total Debt Obligation | $48,750,000 | 6.5% | 25 years | ~$3,900,000 | Year 26 |
§4.2 — Debt Service Profile (Selected Years)
| Year | Opening Balance | Interest | Principal | Total Debt Service | Closing Balance |
|---|---|---|---|---|---|
| Close | — | — | — | — | $48,750,000 |
| 1 | $48,750,000 | $3,169,000 | $731,000 | $3,900,000 | $48,019,000 |
| 2 | $48,019,000 | $3,121,000 | $779,000 | $3,900,000 | $47,240,000 |
| 5 | $44,871,000 | $2,917,000 | $983,000 | $3,900,000 | $43,888,000 |
| 7 | $42,524,000 | $2,764,000 | $1,136,000 | $3,900,000 | $41,388,000 |
| 17 | $28,150,000 | $1,830,000 | $2,070,000 | $3,900,000 | $26,080,000 |
| 25 | $5,200,000 | $338,000 | $3,562,000 | $3,900,000 | $1,638,000 |
| 26 | $1,638,000 | $107,000 | $1,638,000 | $1,745,000 | $0 |
§4.3 — DSCR Table
| Year | EBITDA EST | Total Debt Service | DSCR | Assessment |
|---|---|---|---|---|
| Year 1 | $15.475M | $3.9M | 3.97× | STRONG Pre-royalty: no royalty outflow — full TMC + commodity EBITDA |
| Year 2 | $9.20M | $3.9M | 2.36× | PASS Royalty ramp begins — DSCR remains well above 1.2× floor |
| Year 5 | $9.44M | $3.9M | 2.42× | PASS Steady state — growing royalty rate offset by commodity growth |
| Year 7 | $9.59M | $3.7M | 2.59× | PASS Debt balance amortising — DSCR improving |
| Year 10 | $9.77M | $3.3M | 2.96× | PASS Strong coverage as principal balance declines |
EBITDA = TMC Revenue + Commodity Revenue − Circular Royalty Paid to Counterparty − Operating Expenses. Commodity revenue ESTIMATED at $18M/yr Year 1 (100 TPD), growing 2%/yr. No DSCR year falls below 1.2× threshold.
§5 — Local Partner Return Analysis (20% SPV Stake)
§5.2 — Return Summary Table
| Metric | Total Project | 20% Partner Share | Source Type |
|---|---|---|---|
| Equity invested | $75M (project cost) | $15M (20% cash equity) | CONFIRMED |
| IRR | 22.4% | 22.4% (pro-rata) | ESTIMATED |
| Equity payback | ~Year 7 | ~Year 7 | ESTIMATED |
| DCF Enterprise Value | ~$310M (8% discount rate) | — | ESTIMATED |
| DCF Equity Value | ~$310M − $48.75M debt = ~$261M | ~$62M (20% of DCF equity) | ESTIMATED |
| 30yr Cumulative FCF | ~$230M | ~$46M (20%) | ESTIMATED |
| Cash-on-Cash Multiple (30yr) | ~15.3× | ~15.3× | ESTIMATED |
| Annual dividends (Year 2+) | ~$5.3M FCF post-debt service | ~$1.06M (20%) | ESTIMATED |
| Debt-free year | Year 26 | Year 26 | DERIVED |
§5.3 — Distribution Timeline
| Period | Status | Total Project FCF | 20% Share | Notes |
|---|---|---|---|---|
| T0 — T0+24mo | Equity deployment + construction | −$15M | −$15M | Equity drawn; construction underway |
| Year 1 (pre-royalty) | TMC + commodity; no royalty paid | ~+$11.6M FCF | ~+$2.3M | Strong DSCR 3.97×; equity reserve builds |
| Year 2 (royalty begins) | Full rolling royalty commences Month 13 | ~+$5.3M FCF | ~+$1.06M | DSCR 2.36×; steady dividend flow begins |
| Year 3–7 | Payback period | ~$5.5M FCF/yr growing | ~$1.1M/yr | ~Year 7 equity payback achieved |
| Year 8–25 | Dividend maturity | $6–9M FCF/yr | $1.2–1.8M/yr | Growing as royalty rate escalates vs. TMC |
| Year 26–30 | Debt-free period | ~$13M+ FCF/yr | ~$2.6M+/yr | Senior debt retired; full FCF to equity |
All return figures above are calculated at the agreed TMC Fee of $150/ton — the Carbotura standard ceiling. This is the confirmed COA rate for this engagement. The standard formula floor ($100/ton) does not apply here. At $150/ton TMC, the COA Reserve ($164.25M) and IRR (22.4%) reflect ceiling-rate performance. Commodity revenues are ESTIMATED at $18M/yr at 100 TPD, growing 2%/yr — upside exists from synthetic graphite pricing, IRA §45V hydrogen credits, and recovered metals markets.
§6 — Coverage and Credit Ratios
§6.1 — Key Ratios Chart
Chart: Key Credit and Investor Ratios — Phase Initial (100 TPD) · Benchmark floors: Reserve/Debt ≥1.5× · DSCR ≥1.2× · MOIC ≥2.5× · Insight: All ratios exceed institutional benchmarks. COA Reserve coverage at 3.37× and asset/cost at 3.81× place this structure firmly in investment-grade infrastructure territory. · Source: Registry §M + model derivations · ESTIMATED
§6.2 — Ratios Table
| Metric | Value | Benchmark | Assessment | Primary Audience |
|---|---|---|---|---|
| COA Reserve / Senior Debt | 3.37× | ≥1.5× (infra lenders) | PASS | Lenders / Debt Capital Markets |
| Full Asset Stack / Project Cost | 3.81× | ≥1.5× (infra lenders) | PASS | Lenders / Equity |
| DSCR — Year 1 | 3.97× | ≥1.2× (senior lenders) | PASS | Senior Lenders |
| DSCR — Year 2 (royalty begins) | 2.36× | ≥1.2× (senior lenders) | PASS | Senior Lenders |
| Equity IRR | 22.4% | ≥15% (PE/infra equity) | PASS | Institutional Equity |
| Equity MOIC (30yr) | ~15.3× | ≥2.5× (PE/infra) | PASS | Institutional Equity |
| IRR–WACC Spread | ~14.4pp (at 8% WACC) | ≥5pp (value creation) | PASS | Institutional Equity |
| Royalty/TMC Ratio (Year 2) | 1.20× ($180/$150) | ≥1.0× from Month 13 | PASS | COA Counterparty |
| Benefit per tonne (30yr avg) | ~$302/ton vs. State A | COA ceiling $150/ton | Surplus from Year 2 | COA Counterparty |
| EBITDA Margin (Year 2) | ~62% | ≥40% (infra) | PASS | All investors |
§7 — Circular Royalty Position ($150/ton TMC)
1. Gross cost displacement is quantified separately from Circular Royalty cash flow. Full net fiscal position reflects both.
2. At steady state, the Circular Royalty is designed to exceed the TMC Fee on a per-ton basis.
3. Circular Royalty payments begin 13 months after corresponding TMC Fee payments and ramp to full run-rate on a rolling basis.
§7.1 — Fiscal Period Blocks (Three Gross Items — Reader Derives Net)
§7.1b — Three-Item Gross Fiscal Chart (Phase Initial — 100 TPD)
Insight: Avoided Disposal (amber) + Circular Royalty (emerald) together exceed TMC Fee (red) from Year 2. Gross items shown independently — reader derives net arithmetic. No net position line.
Source: Locked Assumption Registry — April 2026 · FWDC $75/ton ESTIMATED
(100 TPD)
(to Carbotura SPV)
(from Carbotura SPV)
§7.2 — Year-by-Year Cash Flow Table (Phase Initial)
| Year | Avoided Disposal | TMC Rate | TMC Paid | Royalty Rate | Royalty Received | Surplus (Royalty−TMC) |
|---|---|---|---|---|---|---|
| Yr 1 | $2,737,500 | $150.00 | −$5,475,000 | N/A | $0 | −$5,475,000 |
| Yr 2 | $2,737,500 | $153.75 | −$5,611,875 | 120% | +$6,570,000 | +$958,125 |
| Yr 3 | $2,737,500 | $157.59 | −$5,752,185 | 121% | +$6,787,350 | +$1,035,165 |
| Yr 5 | $2,737,500 | $165.57 | −$6,043,305 | 123% | +$7,251,820 | +$1,208,515 |
| Yr 10 | $2,737,500 | $187.33 | −$6,837,545 | 128% | +$8,538,445 | +$1,700,900 |
| Yr 20 | $2,737,500 | $239.79 | −$8,752,635 | 138% | +$11,784,460 | +$3,031,825 |
| Yr 30 | $2,737,500 | $306.96 | −$11,204,040 | 148% | +$16,177,895 | +$4,973,855 |
§7.4 — COA Lifetime Value Summary (Phase Initial — 30 Years)
| COA Metric | Value | Source |
|---|---|---|
| Lifetime Circular Royalty (30yr, undiscounted) | ~$283M | Derived — year-by-year sum DERIVED |
| Lifetime Avoided Disposal Cost | $82.1M | $75/ton × 36,500 tpy × 30yr ESTIMATED |
| Lifetime Total Counterparty Benefits | ~$365M | Royalty + Avoided Disposal DERIVED |
| NPV of Royalty Cash Flow (8% discount) | ~$73M | DCF basis — ESTIMATED |
| Royalty/Fee Ratio (lifetime) | ~1.34× avg. | Royalty/TMC each year, averaged |
| Benefit per tonne (30yr avg.) | ~$302/ton total benefit vs. State A | $365M / (36,500 × 30) |
| Counterparty payback period | Month 13 (royalty exceeds ongoing TMC from Month 13+) | Rolling lagged structure |
Executive Implications — Circular Royalty Position
- The COA Reserve ($164.25M) represents the present value of 30 years of contracted TMC Fee inflows to the SPV. This is the primary institutional asset — and the source of the senior debt coverage ratio of 3.37×. The reserve is self-liquidating: it converts to cash through TMC Fee collection over the COA term.
- From the counterparty's perspective: Year 1 requires $150/ton TMC with no royalty return. From Month 13, the rolling royalty at $180/ton (Year 2) converts the position to net positive on the royalty line. Combined with $75/ton avoided disposal, the Year 2+ improvement vs. State A is +$101.25/ton — growing to +$211.27/ton by Year 30.
- The 30-year benefit to the counterparty (~$365M undiscounted) is not a cost to the SPV — it is the commercial mechanism that ensures the COA is maintained. The SPV's commodity revenues and the royalty obligation are two sides of a value-sharing structure that makes both parties' continued participation rational.
| Figure | Value | Source / Derivation | Status |
|---|---|---|---|
| CapEx — Phase Initial | $75,000,000 | Carbotura standard: first 100 TPD module | CONFIRMED |
| CapEx — Expanded | $247,500,000 | $75M + 3×$57.5M = $75M + $172.5M | DERIVED |
| Capital structure 20/15/65 | — | Carbotura permanent SPV defaults — Registry §M | CONFIRMED |
| COA Reserve — Phase Initial | $164,250,000 | $150 × 36,500 tpy × 30yr = $164.25M | DERIVED |
| IP License NPV | $45,000,000 | Relief-from-Royalty NPV — Carbotura standard | ESTIMATED pending term sheet |
| Commodity revenue — 100 TPD | $18M/yr Year 1 | Synthetic graphite + hydrogen + recovered metals — ESTIMATED from ACM output yield model | ESTIMATED |
| OpEx — 100 TPD | $8M/yr Year 1 | Labor + utilities + maintenance + G&A — Carbotura standard parameters | ESTIMATED |
| Debt rate | 6.5% | Indicative senior infrastructure debt — US market Q1 2026 | ESTIMATED |
| IRR 22.4% | 22.4% | Project IRR — full 30yr FCF model at $150/ton TMC and $18M commodity Year 1 | ESTIMATED |
| TMC Fee $150/ton | $150/ton | Engagement agreement — Carbotura ceiling rate | CONFIRMED |
| Royalty formula and parameters | 120%/+1pp/13mo | Carbotura standard COA — locked | CONFIRMED |
| Balance sheet basis | US GAAP ASC 360/350 | US entity — Nucor Corporation (NYSE: NUE) · US GAAP | CONFIRMED |
All ESTIMATED figures require validation through Community Feasibility Study and term sheet negotiation. This document does not constitute a prospectus, offering document, or financial advice. SPV Finance defaults auto-applied per Carbotura standard parameters: Option B / Conservative 15% / Interpretation A. US GAAP.