GB2051024A - Process for preparing crystalline sodium silico-aluminate of zeolite A type - Google Patents

Process for preparing crystalline sodium silico-aluminate of zeolite A type Download PDF

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GB2051024A
GB2051024A GB8012730A GB8012730A GB2051024A GB 2051024 A GB2051024 A GB 2051024A GB 8012730 A GB8012730 A GB 8012730A GB 8012730 A GB8012730 A GB 8012730A GB 2051024 A GB2051024 A GB 2051024A
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zeolite
suspension
process according
solution
particles
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Produits Chimiques Ugine Kuhlmann
Ugine Kuhlmann SA
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Produits Chimiques Ugine Kuhlmann
Ugine Kuhlmann SA
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    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01BNON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B33/00Silicon; Compounds thereof
    • C01B33/20Silicates
    • C01B33/26Aluminium-containing silicates, i.e. silico-aluminates
    • C01B33/28Base exchange silicates, e.g. zeolites
    • C01B33/2807Zeolitic silicoaluminates with a tridimensional crystalline structure possessing molecular sieve properties; Isomorphous compounds wherein a part of the aluminium ore of the silicon present may be replaced by other elements such as gallium, germanium, phosphorus; Preparation of zeolitic molecular sieves from molecular sieves of another type or from preformed reacting mixtures
    • C01B33/2815Zeolitic silicoaluminates with a tridimensional crystalline structure possessing molecular sieve properties; Isomorphous compounds wherein a part of the aluminium ore of the silicon present may be replaced by other elements such as gallium, germanium, phosphorus; Preparation of zeolitic molecular sieves from molecular sieves of another type or from preformed reacting mixtures of type A (UNION CARBIDE trade name; corresponds to GRACE's types Z-12 or Z-12L)
    • C01B33/2823Zeolitic silicoaluminates with a tridimensional crystalline structure possessing molecular sieve properties; Isomorphous compounds wherein a part of the aluminium ore of the silicon present may be replaced by other elements such as gallium, germanium, phosphorus; Preparation of zeolitic molecular sieves from molecular sieves of another type or from preformed reacting mixtures of type A (UNION CARBIDE trade name; corresponds to GRACE's types Z-12 or Z-12L) from aqueous solutions of an alkali metal aluminate and an alkali metal silicate excluding any other source of alumina or silica
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W10/00Technologies for wastewater treatment
    • Y02W10/30Wastewater or sewage treatment systems using renewable energies
    • Y02W10/33Wastewater or sewage treatment systems using renewable energies using wind energy

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geology (AREA)
  • Inorganic Chemistry (AREA)
  • Silicates, Zeolites, And Molecular Sieves (AREA)
  • Detergent Compositions (AREA)

Abstract

Process for the semi-continuous preparation of a zeolite A type silicoaluminate of constant and homogeneous quality, which process comprises continuously mixing, with vigorous agitation, a solution of sodium aluminate and a solution of sodium silicate in a container in which the average retention time is from 30 seconds to 20 minutes and the temperature is from 70 to 105 DEG C to form a gel which is subsequently matured over a period of 4 to 7 hours at a temperature of from 80 to 95 DEG C, and wherein during maturing precipitated particles of zeolite are kept in suspension without any shearing force being exerted thereon, or with just enough shearing force to ensure that the particles are kept in suspension. Zeolite A having 95% of crystals with diameter 1-8 pi average diameter 2-4 pi and sequestering power of 120 mgCa/g is claimed.

Description

SPECIFICATION Process for preparing crystalline sodium silicoaluminate of zeolite A type The present invention relates to the industrial preparation of crystallised sodium silicoaluminate of the zeolite A type, having a high ion-exchange capacity in relation to calcium ions and consisting of particles having an average diameter of from 2 to 4Ci, 95% of the particles having a diameter within a range from 1 to 8 .
The main applications of zeolites are based on their well known cation-exchanging properties, which are described for example in the "Comprehensive Treatise on Inorganic and Theoretical Chemistry" by J. W. MELLOR, vol. VI, part 2, Longman Editors 1925, pp. 575-579. Zeolites are particularly useful for the sequestration of calcium ions.
To enables zeolites to be used as a substitute for phosphates in washing and rinsing agents, they must have the highest possible ion-exchange capacity, whilst remaining in suspension in the aqueous solutions so as to prevent undesirable deposits on laundry after washing and rinsing. This is why it is essential that the particle size be as small as possible, preferably around an average diameter of 2 to 3 .
The conditions of synthesis of zeolite A (of general formula Na2O. Al203.2SiO2. xH2O, wherein x varies from 1 to 8 but is generally equal to 4 or 5) have been known for a number of years, particularly from "lon-Exchange" by Friedrich HELFFERICH, 1962, McGraw-Hill Book Company, chap. 2, pp. 10-16. The conditions influencing the particle size distribution of the zeolite formed have also been studied, for example, in "Kinetic studies on the formation of zeolite A" by W. MEISE and F. E. SCHWOCHOW in "Molecular Sieves" 121 (1973) pp. 169-178.
Numerous patents describe the conditions of preparation which cause variations in the quality of the raw materials, the reaction temperature, the method of addition of the reagents, etc.
German Patent Application No.25 17218 describes, in particular, the use of shearing forces in the course of the crystallisation stage, and the optional maturing stage which follows, in order to obtain zeolite A having an average particle size of up to 6.5,a, but with an unspecified sequestering power.
In our French Patent Application 78/35344, we have described a process for the semi-continuous preparation of zeolite A, which comprises carrying out instantaneous and continuous mixing of solutions of sodium aluminate and sodium silicate in a container in which the average retention time is from 30 seconds to 20 minutes, to form a gel which is subsequently crystallised discontinuously. This process yields a zeolite A the sequestering power of which is from 110 to 120 mg Ca++/g of anhydrous product, and which has particles of sizes from 2.9 to 6Su, the particle size distribution curve indicating that 90% of the particles have a diameter of less than 11,u.
We have now perfected a process for obtaining a zeolite A which has a sequestering power of more than 120 mg Ca++/g of anhydrous product, and which has a particularly fine and restricted particle size, the average diameter of the particles being from 2 to 4,a. This product therefore proves particularly valuable as a sequestering agent for Ca++ ions for use in washing powders.
According to the present invention there is provided a process for the semi-continuous preparation of a zeolite Atype silicoaluminate of constant and homogeneous quality, which process comprises continuously mixing, with vigorous agitation, a solution of sodium aluminate and a solution of sodium silicate in a container in which the average retention time is from 30 seconds to 20 minutes and the temperature is from 70 to 105"C, to form a gel which is subsequently matured over a period of 4 to 7 hours at a temperature of from 80 to 95"C, and wherein during maturing precipitated particles of zeolite are kept in suspension without any shearing force being exerted thereon, or with just enough shearing force to ensure that the particles are kept in suspension.
Mixing of the solutions of sodium aluminate and sodium silicate is carried out at a temperature of from 70 to 105"C with the maximum possible stirring, in order to obtain a perfectly homogeneous gel.
This gel stays in the reactor for an average period of time sufficient to ensure complete formation of the gel, i.e. from 30 seconds to 20 minutes.
The addition of the two reaction solutions, the flow rates of which are regulated, preferably takes place in the high suction zone created by a turbine the rotation speed of which must be greater than 2,500 r.p.m. The mixing and sheering action of this turbine is further increased if it is placed in a fixed saucer which rotates at the same time as the turbine.
The sodium silicoaluminate gel thus continuously prepared is transferred, by overflowing, into a second reactor comprising a system which enables the product obtained to be kept in suspension and maintained art a constant temperature of from 80 to 95"C to permit crystallisation of the zeolite A. This crystallisation thus occurs discontinuously, the retention time in the crystallisation tank being from 1 to 15 hours, preferably from 4to 7 hours.
When the zeolite is put into and kept in suspension by means of a stirrer, this stirrer rotates at a speed such that the tangential speeds are from 0.2 to 5 m/s.
The process can also be effected by the use of ultrasonic waves, convection currents caused by local heating, or by the use of a jig, which is a mechanical concentrator which effects separation of heavy grains from light grains by relying on the different abilities of the different grains to penetrate a semistationary bed. Such jigs are described, for example, in Handbook of Mineral Dressing, by Arthur F. Taggart, J. Wiley & Sons Inc, Section 11, Page 4.
The discontinuous crystallisation carried out under these conditions means that the particle size of the end product can be controlled at will, and at the same time particularly high sequestering powers are obtained. This result is obtained by adjustment, in coordinated manner, of the following parameters: temperature, retention time, speed of agitation and concentration of the reagents.
The continuous preparation of the gel gives the desired properties when the sodium aluminate solutions are characterised by a weight ratio of Awl203 Na2O of from 0.5 to 1.5, with an aqueous concentration of Na2O of from 30 to 200 g/l, and when the sodium silicate solutions are characterised by a weight ratio of SiO2 Na2O of from 1.5 to 3.5, with an aqueous concentration of Na2O of from 20 to 120 g/l.
The sodium aluminate solutions are preferably obtained either by reacting hydrated alumina with a sodium hydroxide solution, or by taking them from a Bayer cycle forthe production of alumina. The sodium silicate solutions are preferably prepared from raw silica and soda materials which can vary according to the economic criteria involved, e.g.
powdered industrial sodium silicate, industrial sodium silicate solutions, silica contained in sand and soda, soda and silica gel recovered from the fluorosilicicacid residue from a plant for the production of aluminium fluoride or hydrofluoric acid, or from the treatment of the gases released in the processing of natural phosphates, or sodium silicate obtained from a plant for the desilication of bauxites before processing in alumina-producing factories, or residual silica obtained in the production of aluminium salts by wet reaction of natural silicoaluminates such as kaolin or clays, or silica obtained thermally, e.g. in the production of magnesium, silicon metal or silicon alloys.
The mixture obtained by adding these solutions of Na aluminate and silicate together should have a weight ratio of Awl203 SiO2 of from 0.5 to 1.2 and the Na2O content should be adjusted so that the soda concentration of the liquor in which this crystallisation is carried out after precipitation is not more than 135 g/l of NaOH, to prevent crystallisation of the inactive silicoaluminates ofthe feldspar type, but is not less than 26 g/l of NaOH, to ensure that the rate of crystallisation of the zeolite A is compatible with industrial production.
After a maturing period for the crystals of from 1 to 15 hours, preferably 4to 7 hours, a suspension of zeolite A in the liquor as described above is obtained. This suspension is then subjected to suitable solid/liquid separation (for example, filtering, decanting or centrifuging).
The solid thus separated is washed with water and then dried. The washing water is recovered and mixed with the liquor separated from the solid. All this residual water is recycled in order to prepare the sodium atuminate solutions required for the production process.
Drying may cause agglomeration of the crystals.
Since this is prejudicial to satisfactorily keeping the zeolite A in suspension in the detergent solution, it is then necessary to carry out selection or separation of the particles or both operations combined, by any suitable method.
The zeolite A produced by the process described above has the following characteristics: - narrow particle size distribution, 95% of the particles having a diameter within the range from 1 to 8E.L.
- a very fine and very restricted average particle size of from 2 to 4,a which can be adjusted depending on the intended use.
- a calcium ion-exchanging capacity of more than 120 mg Ca++ per gram ofanhydrous product.
-a pH offrom 10to 11 forthezeoliteAin a 1% aqueous suspension.
This zeolite A is particularly suitable for use in washing powders for softening hard water.
The following Examples illustrate the invention.
EXAMPLE 1 A sodium silicoaluminate of the zeolite A type is prepared by continuously mixing a sodium silicate solution A with a sodium aluminate solution B in a reactor which permits instantaneous mixing of the two solutions. The gel obtained is subjected to discontinuous maturing in a maturing vessel.
The sodium silicate solution A is obtained by dissolving crystalline commercial grade sodium silicate in demineralised water at 50"C. It has the following characteristics: SiO2concentration 138 g/l Na2O concentration 41 gIl temperature = 50"C at the moment of use The sodium aluminate solution B is obtained by dissolving hydrated alumina in concentrated soda at 104"C so as to obtain: AI2O3 concentration 56 g/l Na2O concentration 80 gll temperature = 92"C at the moment of use The solutions A and B are simultaneously passed into a reactor fitted with a turbine rotating at 8000 rpm.The solutions A and B have flow rates such that the retention time in the reactor is 2 minutes, whilst the weight ratio of Al2OSiO2 is 1.4.
The gel thus obtained is transferred, by decanting, into the maturing vessel. The sodium silicoaluminate is kept in suspension at 80 C by using a bladetype agitator rotating at 20 rpm.
After 15 hours maturing, the zeolite is separated off by filtration and then washed and dried until a product containing 20 to 22% of hydration water is obtained.
The zeolite thus obtained has the following properties: (a) An X-ray diffraction diagram indicating that more than 87% of the product is crystallised zeolite A.
(b) A particle size characterised by: an average diameter of the particles of 3.9,u 97% of the particles having a diameter less than 8,a 1% of the particles having a diameter less than 1 CL (The particle size is measured by means of an X-ray sedimentometer).
(c) A sequestering power of 121 mg of Ca per gram of anhydrous product. This property is meas ured by reacting a known quantity of zeolite with an aqueous solution containing 200 mg of calcium per litre (50" of hardness and a pH of 10), with vigorous stirring for 15 minutes at 22"C. Some of the calcium ions are fixed by the zeolite. After filtration and rinsing of the latter, the calcium remaining in solution is measured in this filtrate by potentiometric titration using a calibrated solution of ethylene diamine tetra-acetic acid.
EXAMPLE2 The following solutions are prepared by the method given in Example 1: Solution A: SiO2 concentration 119 g/l Na2O concentration 36 gll temperature = 90" at the moment of use Solution B: Al203 concentration 97 gll Na2O concentration 99 g/l temperature = 90" at the moment of use.
Solutions A and B are simultaneously passed into the high suction zone of a turbine placed in a reactor.
This turbine rotating at 300 r.p.m. is placed in a saucer rotating on itself. This saucer consists of two plates the concave portion of which is directed towards the turbine. These two plates define a space into which the two reaction solutions are injected.
Solutions A and B have flow rates such that the retention time in the reactor is 12 mins, whilst the ratio of Al203 to SiO2 is 1.35.
The gel thus obtained is transferred by overflow into a maturing tank. The sodium silicoaluminate is kept in suspension at900C by using a blade-type agitator rotating at 20 r.p.m.
After 5 hours maturing, the zeolite is separated by the same methods as in example 1.
The zeolite thus obtained has the following properties : (a) more than 93% of the product is crystalline zeolite A.
(b) particle size characterised by: average particle diameter 3.0y 99% of the particles have a diameter less than all the particles have diameter largerthan (c) sequestering power (determined as in Example 1) = 129 mg of Ca per g of anhydrous product.
EXAMPLE 3 Sodium silicoaluminate is prepared from the solutions and according to the method described in Example 2, the only difference being the speed of agitation in the maturing tank, which is maintained at 140 r.p.m. for 5 hours.
At the end of this period, the zeolite is separated by the same methods as in Example 1.
The zeolite thus obtained has the following properties: (a) more than 91% of the product is crystalline zeolite A (b) particle size characterised by: average particle diameter 5.2,u 93% of the particles have a diameter less than no particle with a diameter less than (c) sequestering power (determined by the method of Example 1) = 106 mg Ca/g of anhydrous product.
This example shows that too much agitation yields poor results.
EXAMPLE 4 A zeolite is prepared with the solutions and using the method described in Example 2, the only difference being the method of agitation in the maturing tank. Agitation is effected by subjecting the liquid to ultrasonic waves.
After 5 hours, the zeolite is separated by the same methods as in Example 1.
The zeolite thus obtained has the following properties: (a) more than 92% of the product is crystalline zeolite A (b) particle size characterised by: average particle diameter 2.4y all the particles have a diameter less than 4% of particles have a diameter less than (c) sequestering power (determined by the method described in Example 1) = 130 mg Ca/g of anhydrous product.
EXAMPLE 5 A zeolite is prepared using the solutions and method described in Example 2, the only difference being the method of agitation in the maturing tank.
This is effected by convection, by subjecting the liquid to very localised heating atthe bottom of the tank, the excess calories supplied being evacuated by a cold water coil located at the top of the tank.
The average temperature in the suspension is maintained at 90"C by regulating the cooling water.
After 5 hours maturing, the zeolite is separated by the same method as in Example 1.
The zeolite thus obtained has the following properties: (a) more than 94% of the product is crystalline zeolite A (b) particle size characterised by average particle diameter 3.2cm 98% of particles have a diametersmallerthan 8,a all the particles have a diameter largerthan (c) sequestering power (determined by the method in Example 1) = 125 mg Ca/g of anhydrous product.

Claims (12)

1. Process for the semi-continuous preparation of a zeolite A-type silicoaluminate of constant and homogeneous quality, which process comprises continuously mixing, with vigorous agitation, a solution of sodium aluminate and a solution of sodium silicate in a container in which the average retention time is from 30 seconds to 20 minutes and the temperature is from 70 to 105"C, to form a gel which is subsequently matured over a period of 4to 7 hours at a temperature of from 80 to 95"C, and wherein during maturing precipitated particles of zeolite are kept in suspension without any shearing force being exerted thereon, or with just enough shearing force to ensure the particles are kept in suspension.
2. Process according to Claim 1, wherein the suspension of precipitated particles is maintained by the use of ultrasonic waves.
3. Process according to Claim 1, wherein the suspension of precipitated particles is maintained by the use of impellers of the marine screw type or helical impellers with a low shearing level.
4. Process according to Claim 1, wherein the suspension of precipitated particles is maintained by the use of a jig (as hereinbefore defined).
5. Process according to Claim 1, wherein the suspension of precipitated particles is maintained by the use of rollers of the concrete-mixing type.
6. Process according to Claim 1, wherein the suspension is maintained by using localised heating to create convection currents in the solution.
7. A process according to any one of the preceding claims, wherein the solution of sodium aluminate has a weight ratio of Al2ONa2O of from 0.5 to 1.5 with an aqueous concentration of Na2O of from 30 to 200 g/l.
8. A process according to any one of the preceding claims, wherein the solution of sodium silicate has a weight ratio of SiO2/Na2O of from 1.5 to 3.5, with an aqueous concentration of Na2O of from 20 to 120 gull.
9. A process according to Claim 1 substantially as hereinbefore described in the Examples.
10. AzeoliteAtype silicoaluminatewhen pre pared by a process as claimed in any one of the preceding claims.
11. Silicoaluminate of the zeolite Atype wherein 95% of the crystals have a diameter within a range from 1 to 8,zz, the average diameter being from 2 to 4jL, and having a sequestering power of more than 120 mg of calcium per gram of anhydrous product.
12. A washing powder incorporating a zeolite A type silicoaluminate as claimed in Claim 10 or 11.
GB8012730A 1979-04-24 1980-04-17 Process for preparing crystalline sodium silicoaluminate of zeolite a type Expired GB2051024B (en)

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FR7910323A FR2454997A1 (en) 1979-04-24 1979-04-24 ZEOLITE CRYSTALLIZATION DURING INDUSTRIAL MANUFACTURING PROCESSES

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4661333A (en) * 1982-06-21 1987-04-28 Internationale Octrooi Maatschappij "Octropa" Bv Aluminosilicates
US5474753A (en) * 1990-11-09 1995-12-12 Laviosa Rhone-Poulenc Preparation of crystalline 4A zeolites
WO2010128342A1 (en) 2009-05-06 2010-11-11 Barchem Llc Zeolite 4a with new morphological properties, its synthesis and use

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DD292432A5 (en) * 1989-04-10 1991-08-01 ������@������������k�� METHOD FOR PRODUCING A FINE-PARTICULAR TYPE 4A CRYSTALLINE ZEOLITE POWDER WITH PREDETERMINABLE GRAIN SIZE DISTRIBUTION
FR3076828A1 (en) * 2018-01-15 2019-07-19 Arkema France PROCESS FOR THE PREPARATION OF CONTINUOUS ZEOLITES BY MEANS OF ULTRASOUND
DE102018107430A1 (en) * 2018-03-28 2019-10-02 Dimos Maschinenbau Gmbh transport vehicle

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1280877A (en) * 1961-01-14 1962-01-08 Socony Mobil Oil Co Process for preparing crystalline zeolites
GB1115489A (en) * 1964-07-31 1968-05-29 Deputy Minister A process to manufacture crystalline synthetic zeolites for use as molecular sieves
US3425800A (en) * 1967-10-05 1969-02-04 Aluminum Co Of America Production of crystalline zeolites
AT322511B (en) * 1970-06-15 1975-05-26 Martinswerk G M B H Fuer Chem PROCESS FOR THE DIRECT MANUFACTURING OF A PURE CRYSTALLINE ZEOLITHIC MOLECULAR SCREEN WITH A PORE WIDTH OF 4Å.
DE2651485A1 (en) * 1976-11-11 1978-05-24 Degussa TYPE A I CRYSTALLINE ZEOLITE POWDER
FR2398698A1 (en) * 1977-07-29 1979-02-23 Ugine Kuhlmann ZEOLITHE A CONTINUOUS INDUSTRIAL MANUFACTURING PROCESS
US4150100A (en) * 1978-06-13 1979-04-17 Pq Corporation Preparing zeolite NaA

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4661333A (en) * 1982-06-21 1987-04-28 Internationale Octrooi Maatschappij "Octropa" Bv Aluminosilicates
US5474753A (en) * 1990-11-09 1995-12-12 Laviosa Rhone-Poulenc Preparation of crystalline 4A zeolites
WO2010128342A1 (en) 2009-05-06 2010-11-11 Barchem Llc Zeolite 4a with new morphological properties, its synthesis and use

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MA18823A1 (en) 1980-12-31
CA1150711A (en) 1983-07-26
FR2454997A1 (en) 1980-11-21
RO79835A (en) 1983-02-15
PH16460A (en) 1983-10-14
FI67792C (en) 1985-06-10
IN154062B (en) 1984-09-15
DK173180A (en) 1980-10-25
ES490827A0 (en) 1981-11-16
AR223215A1 (en) 1981-07-31
PL223685A1 (en) 1981-02-13
YU112680A (en) 1983-06-30
DE3015415C2 (en) 1982-08-12
GR67291B (en) 1981-06-29
RO79835B (en) 1983-02-28
LU82383A1 (en) 1981-12-02
TR21137A (en) 1983-11-22
OA06574A (en) 1981-07-31
PT71133A (en) 1980-05-01
NO801181L (en) 1980-10-27
AU532923B2 (en) 1983-10-20
IT8067646A0 (en) 1980-04-23
DD150738A5 (en) 1981-09-16
FI67792B (en) 1985-02-28
AU5772380A (en) 1980-10-30
FI801322A (en) 1980-10-25
EG14269A (en) 1983-12-31
JPS569213A (en) 1981-01-30
IT1129078B (en) 1986-06-04
GB2051024B (en) 1983-01-12
CH646400A5 (en) 1984-11-30
SE8003020L (en) 1980-10-25
FR2454997B1 (en) 1983-09-23
BE882821A (en) 1980-10-17
HU183168B (en) 1984-04-28
ES8200627A1 (en) 1981-11-16
BR8002468A (en) 1980-12-09
DE3015415A1 (en) 1980-10-30
ZA802441B (en) 1981-04-29

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