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Title: The%20Archimedes%20Filter


1
The Archimedes Filter
  • John R Gilleland

2
Hanford Site Location
WTP

3
Potential Location of Archimedes Filter Plant at
Hanford
4
Hanford Tank Waste is Extremely Challenging to
Process
  • Hanford tanks hold 53 million gallons of Defense
    Waste
  • 26 wt sludge
  • 44 wt saltcake
  • 30 wt supernatant
  • Archimedes is focused on the sludge fraction, the
    most challenging to process
  • chemical complexity with different past
    operations and subsequent mixing
  • significant variability from batch to batch
  • Hanford has planned an aggressive campaign to
    chemically separate this material in order to
    reduce the volume of waste that must be vitrified
    as High Level Waste (HLW) glass.
  • There is great uncertainty and practical limits
    to the effectiveness of chemical separations due
    to
  • waste inventory uncertainty
  • batch sampling uncertainty
  • chemical processing times
  • processing temperatures required
  • unintended chemical reactions
  • recycle streams
  • additional waste generated from added agents, etc.

5
Hanford ORP Solids Dissolution Targets Result in
IHLW ReductionArchimedes Offers an Alternative
for Even Greater Reduction
  • Hanfords baseline targets dissolution of 90 of
    the tank HLW oxides to yield an inventory of
    9,860 MT solids to be sent to vitrification,
    producing 34,676 MT of HLW glass and take 22
    years to process.2

Notes (1) HLW glass production assumes ORPs
relaxed glass model. (2) Assumes 6 MTG/day
with 70 utilization for HLW Vit and 1.1 MT
oxide/day per Archimedes Filter with 70
utilization.
6
Archimedes Approaches the Problem from a Physics
Perspective Separating HLW Oxides Based on Atomic
Mass
Hanford HLW Solids(17,553 MT Water Washed
Solids Inventory)
  • Archimedes Filter Separates heavy from light
    ions.
  • This effectively separates radioactive from
    non-radioactive elements.
  • The Filter could isolate 99.9 of the
    radioactivity in just 10 of sludge mass.
  • Thus, deployment of Archimedes at Hanford enables
    up to 90 of the HLW sludge to be treated as Low
    Activity Waste.
  • Separation of ions in plasma is relatively
    indifferent to the chemical complexity of waste
    feed.

Radioactivity
Waste Mass
99.9
Heavy Fraction
10
AMU 89
90
Light Fraction
0.1
7
Company Mission
  • From the time of its founding in 1998 Archimedes
    primary corporate mission has been the
    development of a breakthrough separations
    technology for treatment of high level waste from
    nuclear weapons production.
  • A new invention, called the Archimedes Filter,
    promises to reduce the required number of HLW
    canisters at Hanford by up to 85.
  • Archimedes has raised 100 million dollars of
    private funds to insure speed, flexibility and IP
    ownership necessary to support this mission.
  • An international team of 12 institutions supports
    the Filter technology development as well as
    associated systems development, plant design and
    licensing work for US waste site applications.
  • Archimedes now believes that our development of
    plasma based separation represents a platform
    technology that may be applied to commercial
    endeavors such as spent fuel recycling.

8
Archimedes Team Has Deep Domain Expertise
  • Archimedes has attracted a world-class team of
    physicists, chemists, and engineers, including
  • Tihiro Ohkawa Chairman Vice
    Chairman, General Atomics Company John
    Gilleland CEO Chief Scientist
    and VP Commercial Programs, Bechtel
  • Larry Papay Senior VP SVP, SAIC,
    Bechtel and Southern California Edison
  • Richard Freeman VP Science Tech. Dev.
    General Atomics Company, RF Physics Leigh
    Sevier VP Engineering General
    Atomics, Princeton, Plasma Systems Stephen Agnew
    Senior Chemist Los Alamos
    Chemical Sciences Division Sergei Putvinski
    Senior Physicist International
    Thermonuclear Experimental Reactor
  • Government Relations
  • David Gerson, Vice Chairman of Archimedes is also
    Executive Vice President of the American
    Enterprise Institute and a former Associate
    Director of the White House Office of Management
    and Budget (OMB)
  • Daniel Evans, Director of Archimedes, former
    United States Senator and Governor of the State
    of Washington
  • John Wagoner, Vice President of Archimedes,
    former DOE Hanford Site Manager (1990-1999)
  • Business
  • Scott Tierney, President and Chief Operating
    Officer, former Morgan Stanley investment banker
  • Industry Consultants
  • Harold Forsen, former VP Bechtel, member National
    Academy of Engineering
  • David McAlees, former President Siemens Nuclear
    Fuels
  • Harry Harmon, former Hanford tank waste manager
  • Greg Choppin, Professor of Nuclear Chemistry,
    Florida State University
  • Archimedes has also attracted prominent
    scientists as investors in the Company
  • Ted Geballe, Stanford University, Professor
    Emeritus in Applied Physics
  • Daniel Koshland, UC Berkeley, Professor
    Emeritus, past Manhattan Project scientist
  • Ken Fowler, former Associate Director Lawrence
    Livermore National Labs

9
Archimedes Has Created a Global RD EffortKey
Partnerships Have Helped us Meet Technical
Milestones
Demonstration Program Commercial Plant Collaboration / Role in the Archimedes Process
UC San Diego ? Physics tests and diagnostics equipment Start-up electrode
UC Berkeley ? Physics tests and diagnostics equipment
Univ. of Texas ? Physics tests and diagnostics equipment Plunge probe
St Petersburg Univ. Russia ? Torch used to vaporize waste into Filter Studies on molten NaOH
Budker Institute Novosibirsk, Russia ? Electrode/ Light Collector Design and fabrication Electrode power supply design and component fabrication
CEA, France ? Calcination of HLW and LAW waste Glass studies Off-gas
EDF, French Utility ? Two visiting scientists/engineers
Oak Ridge Natl Lab ? ? RF Antenna Modeling Conceptual Design Remote Maintenance
Battelle/PNWD ? Pacific Northwest Division. Hanford process flow Archimedes integration and cost savings analysis chemical engineers
Westinghouse SMS ? Criticality Safety analysis for commercial plant design
Jacobs Engineering ? Hanford Teaming Agreement Partner (Plant Design) Conceptual Design AFP Design Balance of Plant
Cogema/SGN ? Conceptual Design Off-gas treatment Waste removal Systems design
Nuvotec ? Filter plant detailed process flow model
BWXT ? Hanford Teaming Agreement Partner (Plant Operator)
10
Archimedes Plasma Mass Filter Separates Ions by
Mass
  • Filter takes advantage of the mass gap in
    Hanford tank waste between radioactive and
    non-radioactive species.

Na-23 Al-27 Fe-56
Sr-90 Cs-137 TRU
Archimedes Filter Function

90 mass

100

99.9

radionuclides

relative amount

50
59

89

atomic weight (g/mol)

11
Filter Subsystems
RF Antennas (Ionize Waste)
Electrodes (Rotate Plasma)
Light Collector
Heavy Collector
Sub-Micron Powder Injector
12
The Archimedes Two Filter Plant is Small and has
Modest Infrastructure Needs
13
Hanford ORP Solids Dissolution Targets Result in
IHLW ReductionArchimedes Offers an Alternative
for Even Greater Reduction
HLW Glass Estimates (MT)1
HLW Solids 84,403 MT
17,553 MT
10,100 MT 9,858 MT
HLW Glass 272,000 MT
73,000 MT
46,100 MT 34,676 MT
(ORP revised target)
Archimedes Filter Plant
50 of W.W Solids
Reduction of 17,000MT HLW Glass
  • Hanfords baseline targets dissolution of 90 of
    the tank HLW oxides to yield an inventory of
    9,860 MT solids to be sent to vitrification,
    producing 34,676 MT of HLW glass and take 22
    years to process.2
  • Deployment of a 2-Unit Archimedes Filter Plant
    could process 50 of the W.W. Solids inventory
    would yield a total reduction of 17,000MT HLW
    glass produced by WTP.
  • provides WTP operational flexibility as an
    alternative pre-treatment path for HLW solids

Notes (1) HLW glass production assumes ORPs
relaxed glass model. (2) Assumes 6 MTG/day
with 70 utilization for HLW Vit and 1.1 MT
oxide/day per Archimedes Filter with 70
utilization.
14
Integration of Archimedes offers Broad Technical
and Operational Benefits for Hanford and the WTP
  • Provides an alternate pretreatment path for HLW
    solids to HLW vitrification operations
  • Reduced burden on the HLW melter performance and
    utilization requirements due to significant
    reduction of solids inventory and removal of key
    elements that limit waste loading in the HLW
    glass, such as chrome, sulfate and phosphate
  • Filter separation process is less vulnerable to
    waste batch uncertainty and variability
  • Could eliminate need for Oxidative Leaching
    process
  • Net reduction of ILAW glass due to reduction of
    caustic leaching and sodium added
  • Reduces residual environmental impact by
    directing 99Tc and 129I to IHLW rather than ILAW
  • Reduces burden on HLW interim storage,
    transportation and repository requirements

15
Archimedes Filter Plant Deployment AnalysisWaste
Inventory Based on ORP Refined Target Case,
RPP-23412
  • Deployment of 2-Filter Archimedes Filter Plant
    (AFP) would
  • treat selected batches (46 of water-washed
    solids mass) over 14 years
  • reduces overall IHLW glass production by 50
  • reduces estimated WTP processing time by 8 years

WW Solids Treatment Path 1 WTP Only WTP with 2-Filter AFP
Archimedes Filter Plant 0 46
WW Solids Pretreatment by WTP 100 54
IHLW MT Glass Produced 2 34,000 17,000
Processing Years 4 Processing Years 4 Processing Years 4
WTP Operations 3 22 14
Completion 4 2037 2029
Notes 1 Estimated 17,550 MT HLW water washed
solids in 590 batches 2 Assumes DOE "relaxed"
glass model 3 Assumes 6 MTG/day with 70
utilization for HLW Vit and 1.1 MT oxide/day per
Archimedes Filter with 70 utilization. 4
Assumes startup in 2013 plus 2 years
commissioning (no production)
16
How the Archimedes Filter Works
17
How the Filter Works
Magnet Coils
Magnetic field
Heavy ions
Electric field
Electric field
Light ions
Electrodes
Electrodes
Waste injected as sub-micron powder
Side view of the plasma column
18
Filter Physics Ions are Guided by Electric and
Magnetic Fields
Axial magnetic field (B) confine light ions
(blue) Radial electric field (E) expels heavy
ions (red)
B
side view
end view
Radial force balance on ions of mass m and charge
Ze rotating with speed vq
electric
magnetic
centrifugal
Heavy ions are expelled if their mass exceeds the
cutoff mass mc
19
Effects of Collisions Simulated with Monte-Carlo
Model
  • Design of Archimedes Filter Plant requires a high
    throughput 0.26 ion-mol/s.
  • Collisions between ions and other plasma
    particles can degrade separation.
  • Monte-Carlo computer simulation tracks ion
    trajectories in Filter E and B fields, including
    collisions with background plasma and neutrals.
  • Good separation at high density with reasonable
    electric and magnetic fields

Light Elements
Light Elements
Heavy Elements
Side View
End View
Each curve shows the trajectory of an ion in the
plasma
20
Archimedes Filter Process
plasma formation
LAW
rotation / separation
aqueous slurry
collection / removal
IHLW
feed preparation
injection
21
Photo of DEMO - the Archimedes DEMOnstration Unit
Vacuum pumps
RF Transmission Lines
Magnetic Field Coils
Electrodes
Vacuum Vessel
22
Demo Diagnostics
Gattling Gun (Heavy Coupons)
Bolometer
IR Inspection Periscope
LIBS-L
Plunge Probe w/4 Point Tip
LIBS-H
Light Coupon System (Both Sides)
Heavy Collector
Boroscope
Light Coupon and Handler
Microwave Interferometer
Light Collector
Optical Arrays
23
So How Is It Working So Far?
24
Filter DemonstrationOverview
  • Six steps will separate waste into LAW and HLW
    streams
  • Feed preparation receive water-washed slurry
    from waste tanks calcine and convert to powder
    for injection into Filter
  • Injection deliver waste to Filter in a form that
    plasma can digest
  • Plasma formation convert injected waste to
    plasma ions
  • Rotation/Separation rotate waste plasma to
    separate heavy ions from light ions
  • Collection Accumulate distinct light and heavy
    waste deposits at collectors
  • Removal Clean collectors to remove heavy and
    light waste deposits
  • This talk will give results for each step to
    date, and describe the objectives to demonstrate
    each step on Hanford surrogates

25
Feed Preparation Process Will Convert Water
Slurry to Calcined Powder
aqueous slurry
feed receipt initial sizing / milling
spray drying to lt 50 mm powder
Feed preparation
ICP
calcination, submicron powder production
Filter
sizing particle / gas separation
26
Calcination and Conversion of Surrogate to Dry
Powder has been Demonstrated


Spray Dryer System to be tested with Niro Inc.
Plasma Calcination System tested with CEA
  • Niro Inc. has successfully completed feasibility
    testing with Hanford surrogate elements, and is
    ready to perform a pilot study on the full
    surrogate
  • Plasma calcination from slurry to dry powder has
    been demonstrated with Hanford Envelope D
    surrogate at CEAs Marcoule facility in France.

27
Generation of Sub-Micron Powders from Hanford
Surrogate has been Demonstrated On-Site
  • Conversion of waste surrogate (representative of
    AZ-101) from spray-dried dimensions to sub-micron
    scale has been demonstrated on-site
  • Optimization of vapor condensation conditions
    will allow control of conversion efficiency and
    powder size
  • Calcination efficiency of this process needs to
    be characterized

ICP input waste surrogate powder with typical
dimension 20 mm
ICP output surrogate powder with typical
dimension lt 1 mm
28
Direct Powder Injection System is Installed at
the Demo Filter
Powder Injection in Plasma
Injection Nozzle
Powder Plume
Evaporation Model
  • A fluidized bed delivery system is currently
    installed on the Demo Filter. 0.05 mm powders
    have been radially injected into the Filter with
    low driving gas flow rates
  • Injection rates up to 2 g/s have been reached
    (target is 5 g/s)
  • Modeling of particle trajectories in the Filter
    plasma predicts full evaporation of 0.20 mm
    alumina particles

Powder Injection Nozzle
29
Waste Throughput is Maximized by Control of
Plasma Shape
Plasma center
  • The RF power deposition profile is controlled by
    phasing of currents in each antenna strap
  • Flat density profiles will maximize waste
    throughput and ionization efficiency

30
Conversion of Submicron Surrogate Powder into
Plasma has been Demonstrated
  • A complex waste surrogate (75 Al2O3, 15
    Fe3O4, 6 ZrCaO3, 4 BiO2) has been injected
  • Emitted light measurements from the plasma
    indicate successful evaporation and conversion to
    plasma ions
  • Current work is focused on maximizing ionization
    efficiency and throughput through injection
    control
  • The injection region is controlled by injection
    nozzle shape and location

RF power ramps up
Ion Light Intensity
Alumina powder injection starts
31
Separation Demonstration Geometry
Heavy Collector
Light Collector
Surrogate Vapor
  • Separation experiments were performed with edge
    injection of AZ-101 surrogate by laser
    evaporation
  • Major constituents in AZ-101 target Si, Al, Fe,
    Zr, Bi
  • Spectroscopic measurements (red lines) and
    surface coupon measurements (red arrows) are used
    to study injected surrogates

32
Plasma Profiles are Ideal for Separation
Plasma center
Plasma center
  • Source control in sodium plasma maintains filled
    profiles in rotating plasma
  • A parabolic electric potential applied to the
    light collectors causes the plasma to rotate
  • Probe measurements in the plasma show that the
    applied potential penetrates along the magnetic
    field

33
Doppler Measurements Confirm Rigid Body Rotation
at E x B Velocity
  • Doppler spectroscopy measures plasma rotation
    speed in the Heavy Collector region for Bi and Fe
    from injected Hanford AZ-101 Surrogate
  • Rotation scales with applied electric field

34
Applying Cutoff Electric Field Sends Heavy
Elements to the Heavy Collector
  • Battelle AZ-101 tank waste surrogate injected
    into sodium background plasma by laser
    evaporation
  • 100 V bias at 900 Gauss (cutoff mass 134 AMU)
    used to separate bismuth (208 AMU) from lighter
    elements

35

Surface Measurements at Light and Heavy
Collectors Show Cutoff of Bismuth at Expected
Voltage
Light Collector
Light Collector
Heavy Collector
Heavy Collector
Bi Vc63.6V
No cut-off 99 of collected sodium is on the
light collector
Below cut-off 99 Bismuth -gt light
collector Above cut-off 85 Bismuth -gt heavy
collector 15 Bismuth -gt light collector
36
Filter Function Matches Numerical Simulation for
Edge Injection
Si
Fe
Zr
Bi
  • ICP and XRF diagnostics give similar results
  • Edge injection of vapor leads to scrape-off
    effect
  • Monte Carlo simulations using measured plasma
    parameters are in quantitative agreement with
    the data

37
Full Throughput Demonstration Filter Simulation
Shows Good Cutoff of Heavy Elements
Al
Na
Cr
Fe
Bi DF400
Cs DF900
Sr DF30
Cutoff 84 AMU
  • Monte Carlo simulation at full Filter density,
    magnetic field, and electric field show high
    decontamination factors for heavy elements
  • Injection for this simulation is at radii less
    than 20 cm

38
Higher Density and Magnetic Field of AFP Improves
Filter Function
  • The AFP Filter will operate at slightly higher
    density and magnetic field, and has a different
    collector geometry

39
Hanford Test Program High Throughput Separation
Optimization
  • The tests will confirm that the Filter can
  • Separate Hanford waste at high throughput rates
    and achieve separation decontamination factors
    matching those specified below

Radionuclides Percent of HLW Batches Percent of WTP Contract Allowance for On-site Disp. Minimum Required AFP DF AFP Target DF Hanford Test Program Target DF
TRU 95 Class C Requirement 76 gtgt100 gtgt100
Sr-90 100 20 50 100 30 - 60
Cs-137 100 4 60 gtgt100 gtgt100
40
Light Ion Collection
  • Conical Electrode/light Collector Design
  • Water-cooled copper rings can
  • withstand full throughput heat loads
  • Collector surface intercepts all ion orbits
  • Insulating stand-offs and feed-throughs are
    protected from the plasma heat
  • Collection rate
  • 5 mm per hour at full demo throughput
  • Access ports available for coupon surface
    sampling of collected deposits

41
Heavy Ion Collector
  • Paddlewheel Design
  • Collector surface intercepts heavy ion orbits
  • Tilted paddles minimize plasma refuelling by
    sputtered heavy particles
  • Open geometry allows neutral gas pumping
  • Collection rates
  • less than 0.15 mm/hr at full Demo throughput
  • Up to 1.5 mm/hr on the plasma edge due to radial
    electric currents
  • Extended operation without cleaning is possible
  • Cooling allows steady state operation at full
    throughput

heavy ion orbit
42
Demo StatusSummary
  • Filter separation physics demonstrated
  • Plasma rotates at required velocity for
    separation
  • Expected decontamination factors are measured for
    heavy elements
  • Separation scales with electrode voltage and
    magnetic field
  • Basic technology solutions demonstrated
  • Surrogate preparation calcination and conversion
    to powder
  • Injection delivery of surrogate into the plasma
  • RF heating conversion of injected surrogate into
    plasma
  • Electrodes plasma rotation and separation
  • Collectors collection and recovery of separated
    surrogate

43
DEMO Parameters are Near Target for Full
Throughput Separation Tests
Parameter Engineering Maximum Value Achieved Hanford Test Program Goal
Plasma Radius (m) 0.4 0.4
Plasma Length (m) 3.9 3.9
Magnetic Field (Gauss) 1600 1500
RF Frequency (MHz) 4 4
RF Power (MW) 3 3
Plasma Density (1e19 m-3) 2.0 2.0
Throughput (ion-mol/s) 0.04 0.1
Electrode Voltage (Volts) 300 500
Ion Temperature (eV) 7 13
Discharge Duration (s) 600 Steady State
44
Plasma Based Separations 21st Century Technology
Solution for Nuclear Waste and a Proliferation
Resistant Commercial Fuel Cycle
45
Background
  • Currently the National Waste Policy Act (NWPA) of
    1982, as amended, limits Yucca Mt. to 70,000 MT
    of spent nuclear fuel
  • 7,000 MT is reserved for DOE defense waste
  • Remaining 63,000 MT is adequate for spent fuel
    from existing fleet of reactors if all plants are
    shut down by 2010
  • 120,000 MT is required if all operating reactors
    are granted 20 yr extensions
  • Geologic exploration indicates Yucca Mt could
    expand to 119,000 MT with NWPA amendment
  • The DOE must report to Congress on the need for a
    second repository in 2010
  • Future repository strategy is likely to
    incorporate actinide burning in advanced
    reactors to reduce storage capacity demands

46
Expected U.S. Repository Needs in 2100 (AFCI
Source)
47
Reprocessing Technologies for Spent Nuclear Fuel
  • Reprocessing to recycle Pu in MOX reactor fuel
    (PUREX)
  • Similar to French La Hague Plant in technology,
    capacity cost
  • 700 acre, 6000 employees, 1700 MT/year capacity
  • FP actinide waste immobilized in borosilicate
    glass
  • After MOX recycle, Pu is separated and stored for
    future reactors
  • Reprocessing to extract uranium (UREX) and
    chemically separate FP from actinides (UREX)
  • Requires U extraction and FP separation, but no
    Pu extraction
  • Uranium recycle or disposal as low-level waste
    (LLW)
  • Cs Sr stored in surface repository for 300
    years, then disposal as LLW
  • Actinides immobilized in glass with disposal in
    Yucca Mt or stored for future use as nuclear fuel
  • Hybrid reprocessing with UREX and Archimedes
    Filter
  • UREX uranium extraction followed by Filter
    separation of FP actinides
  • U extraction (UREX) is the same, but FP
    Pu/actinide separation by physical process
  • Achieves same objectives as chemical reprocessing
    plant with much less by-product radioactive waste
  • Offers cost and schedule advantages

48
Comparison of UREX, UREX and UREX-AFP Process
Streams
49
Archimedes Filter Function Spent for Commercial
FuelGroup Separation
100
0
50
UREX-AFP Mission and High Level Requirements
  • Mission
  • The hybrid UREX pretreatment and Archimedes
    Filter Plant mass separation process will enable
    expansion of Yucca Mt capacity to 250,000 MT of
    spent nuclear fuel.
  • Requirements
  • Process 2000 MT of spent nuclear fuel per year
  • Separation of FP from Pu/actinides sufficient to
    achieve desired repository capacity
  • Provide least environmental impact of all
    alternative technologies
  • Plant startup consistent with first shipments to
    Yucca Mt
  • Provide option to extract Pu if desired

51
UREX-AFP Simplified Flow Sheet (45GWd/MT, 10y
Cooling)
Cladding294 kg
Feed1300 kg
Gas 8.5 kg
CuttingDissolution
Extraction
UREX
UraniumRe-extraction
UraniumStripping
GasTreatment
RaffinateStream35 kg
InsolubleStream24 kg
Uranium936 kg
Tc1 kg
Gas x kg
Pre-treatment
FissionProducts(42 x) kg
ARCHIMEDESFilter
Surface Repository
AFP
Actinides17 kg
Storage or recycle
52
Summary of Process Stream Contents
Elements Spent fuel input(45GWd/MT,10 y cooling) Removed by UREX Raffinate stream Insoluble stream Processed by ARCHIMEDES filter
U (kg/MT) 940.75 936.05 0.94 3.76 4.70
Pu (kg/MT) 11.00 0.00 10.89 0.04 10.93
Minor Actinides (kg/Mt) 1.56 0.00 1.55 0.01 1.55
Fission Produc ts minus Tc 45.34 0.00 21.75 14.61 36.36
Metal cladding (kg/MT) 300.00 0.00 0.00 6.00 6.00
Tc (kg/MT) 1.03 0.98 0.05 0.00 0.05
Total (kg/MT) 1299.68 937.03 35.18 24.42 59.60
100.00 72.10 2.71 1.88 4.59
NB 8.51 kg of gas and 294 kg or metal cladding
are removed after rod cutting and dissolution
53
Implementation Comparison of Alternative
Technologies
  • Reprocessing with MOX fuel recycle
  • High cost and schedule
  • LWR plants may opt to not use MOX fuel
  • Does not expand repository capacity
  • Reprocessing with UREX radio-chemical plant
  • Highest cost and schedule
  • Environmental impact greater than UREX-AFP
  • Significantly expands repository capacity
  • Reprocessing with hybrid UREX and AFP plant
  • Lowest cost and shortest schedule
  • Same repository benefits as UREX radio-chemical
    plant
  • Least environmental impact

54
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