JP5275817B2 - ハロゲンからの軽質ガスの分離 - Google Patents

ハロゲンからの軽質ガスの分離 Download PDF

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JP5275817B2
JP5275817B2 JP2008553404A JP2008553404A JP5275817B2 JP 5275817 B2 JP5275817 B2 JP 5275817B2 JP 2008553404 A JP2008553404 A JP 2008553404A JP 2008553404 A JP2008553404 A JP 2008553404A JP 5275817 B2 JP5275817 B2 JP 5275817B2
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ビー. ガデワー,セイガー
ク. ストイメノフ,ペテル
グロッソ,フィリップ
ダブリュ. マクファーランド,エリック
ダブリュ. ブリード,アシュレイ
ジェイ. ウェイス,マイケル
ディー. ワイルスタ,マイケル
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Description

この発明は、一般に、不活性ガス及び他の化合物をハロゲンから分離するプロセスに関する。
酸化の媒体としての空気と酸素の選択は、多くの工業プロセスについて試された。空気が、反応化学に不利に影響を及ぼすことなく、酸化に用いることができるプロセスについて、減少された資本及び運転費のために、空気は、純酸素供給より好まれる。酸素のより高い原価は、従来、膜または蒸留を用いて酸素を窒素から分離する費用から生ずる。純酸素の使用が空気より好まれる1つの例は、フィッシャー−トロプシュ合成を用いてなし遂げられる天然ガスからの液体炭化水素の生産の第1段階である合成ガス生産にある。反応化学に影響を及ぼすことに加えて、合成ガス発生においての空気の使用は、窒素が未転化天然ガスから分離されることを必要とする。天然ガスからの窒素の分離は、費用集約的であり、従来、膜または圧力スイング吸着を用いて実行される。
不活性ガス流れにおいて微量臭素を捕捉する慣用法は、アルカリ性スクラバー、例えば、NaOH水溶液を使用することである。慣用のスクラビング方法により、捕捉した臭素を回収することは容易ではない。他の慣用法は、そのそれぞれが、捕捉した臭素は回収が難しいという欠点をもつ、亜硫酸ナトリウム、亜硫酸水素ナトリウム、または水酸化カルシウムの水溶液の使用を含む。
サンタバーバラ、カリフォルニア州のGRT、インクにより開発された技術は、高級炭化水素が、炭化水素とハロゲンを反応器において混合してハロゲン化アルキル及びハロゲン化水素、HXを形成することにより、メタンまたは天然ガスから合成されることを許容する。ハロゲン化アルキルとHXは、酸化金属及び類似物質と接触して向けられて高級炭化水素とハロゲン化金属とを形成する。ハロゲン化金属は、その両方が再生される酸化金属及びハロゲンに酸化される。空気が酸化に用いられるときに、発生したハロゲンは、除去されなければ、ハロゲン化区画及び高級炭化水素が生成する結合区画を通過するであろう窒素及び二酸化炭素のような不活性ガスを含む。GRT、インクにより開発された他の技術において、炭化水素は、触媒の存在においてハロゲン化アルキルをハロゲンと反応させることにより形成され、HXは、副生物として形成される。処理全部の後のサイクルで用いるハロゲンを再生するために、HXは、触媒の存在において空気または酸素で酸化される。両方の形式の技術について、ハロゲンが次の処理サイクルで使用される前に、N、COから再生ハロゲン、他の軽質ガス(未反応軽質炭化水素のような)、及び水を分離することが望ましい。循環または連続処理について、そのようなガス、特に窒素は、分離されなければ、急速に蓄積するであろう。明らかな必要性は、不活性ガス及び他の化合物をハロゲンから分離する効率的、原価効率のよい処理について存在する。
本発明によれば、一以上の物理的分離及び化学スクラバーとの接触を用いて、臭素または塩素から一以上の軽質ガスを分離して添加ハロゲンを回収する方法が提供される。本発明の1つの側面によれば、本方法は、(a)ハロゲンを含む一以上の軽質ガスの供給原料を蒸留塔またはフラッシュ蒸発器へ供給すること;(b)蒸留塔またはフラッシュ蒸発器を操作して供給原料を、(i)主量のハロゲンとほんの少量の軽質ガスとを含む第1の液体と、(ii)主量の軽質ガスとほんの少量のハロゲンとを含む第1の蒸気とに分離すること;及び、(c)蒸気を化学スクラバーに供給して蒸気からハロゲンを回収すること、を含む。
本発明の第2の側面において、二以上の物理的分離が使用され、各分離は、逐次に、液相のハロゲン及び気相の軽質ガスそれぞれのより大きい濃縮に導く。例えば、蒸留塔からの蒸気(軽質ガスについて濃縮された)は、さらに物質を新規蒸気と新規液体とに分離する第2の蒸留塔に供給されることが可能であり、新規蒸気は、軽質ガスについてより濃縮され、新規液体は、ハロゲンについてより濃縮される。
本発明において使用される化学スクラバーは、いくつかの実施形態においてハロゲンとのレドックス反応を通して化学的にハロゲンを収着することができる、1つ以上の掃去剤、物質を含む。好ましい物質は、臭化銅(II)(CuBr、「臭化第二銅」)への転換により臭素を収着することが可能である臭化銅(I)(CuBr、「臭化第一銅」)である。
本発明の特徴及び利点は、以下の詳細な説明に照らして考慮されるとき、及び、以下の図面を参照することにより、良く理解されることになるであろう。
この発明の新規方法において、一以上の軽質ガスは、ハロゲンを含む一以上の軽質ガスの供給原料を、主量のハロゲンとほんの少量の軽質ガスとを含む液体、及び、主量の軽質ガスとほんの少量のハロゲンとを含む蒸気に、物理的に分離することにより、臭素または塩素から分離される。添加ハロゲンは、ハロゲン掃去剤を含む化学スクラバーを通過させることにより、蒸気から除去される。ここで使用されるように、「軽質ガス」は、それが混合されるハロゲンより低い沸点を有するものである。大気圧での臭素及び塩素の沸点は、それぞれ、近似的に、59℃〜34℃である。窒素(N)、二酸化炭素(CO)、及び、「軽質炭化水素」−C〜C炭化水素のようなガスは、定義に含まれ、ただし、C炭化水素(ブタン及びブテン)は、塩素の沸点がC炭化水素の沸点未満であるので、塩素が関心のハロゲンである場合には、「軽質ガス」とみなされない。用語「主量」及び「少量」は、相対的であり、主量の第1成分と少量の第2成分を含む液体(または気体)は、第2成分より多い第1成分を含む。一般に、本発明の実施形態の殆どにおいて、所定の液体(または蒸気)は、支配的に一成分(ハロゲンまたは軽質ガス、からなり、他成分がほとんど全くない。
本発明の1つの実施形態は、軽質ガス(この場合に、窒素及び二酸化炭素)を臭素から分離する設備10を描く図1に図解される。臭素を含むN及びCOの供給原料12は、頂部16と底部18を有する蒸留塔14に供給される。熱交換器20、22は、部分凝縮器または全還流として機能を果たし、それぞれ、熱交換器24により達せられる温度の追加的な低下で、臭素が濃縮された液体「残液」(及び、ほんの少量の軽質ガス、典型的には、臭素中の2つのガスの溶解限度以下を含む)が蒸留塔から抜き取られることを許容する。
塔の頂部において、還流ドラムからの液体の全還流は、熱交換器22により促進され、軽質ガスが濃縮された蒸気(及び、ほんの少量の臭素を含む)を生じ、蒸気は、少量の臭素が除去されて軽質ガス(窒素及び二酸化炭素生産量)を生ずる化学スクラバー26に経路を定められる。以下の説明されるように、臭素は、スクラバーからそれを加熱することにより、回収されることが可能である。
本発明の他の実施形態において、(示されない)2つ以上の蒸留塔は、各塔からの連続的な蒸気の軽質ガス濃縮及び「残液」流れの臭素濃縮のために、直列に接続され、各塔のヘッド(蒸気)が次の塔への供給として経路を定められる。
蒸留構成について、臭素の標準沸点が近似的に59℃であることを考慮して、典型的な圧力は、0.1バール〜50バール、より好ましくは5〜20バールの範囲であり、温度が蒸留設備圧力に依存する。段の数は、2〜200、より好ましくは5〜30の範囲であることが可能である。
図2は、図2に示された実施形態の変形を図解し、ハロゲン供給(例えば、Br)がハロゲン再生装置から生ずる。この実施形態において、28からのハロゲン供給は、水吸着装置(乾燥剤を含む)で除去される水を含む。代替的に、供給は、残留水が乾燥剤の水収着カラムで除去され、形成する臭素−水共沸混合物の限界まで、初めに蒸留されて、水から臭素を除去される。
本発明の別実施形態において、1つ以上の気−液フラッシュ分離装置(「フラッシュ蒸発器」)は、ハロゲン及び軽質ガスの供給を分離するために使用され、化学スクラバーにおいての追加の分離が続く。図3は、窒素及び二酸化炭素を含む、臭素の供給が第1フラッシュ蒸発器52に提供される設備50のようなものを図解する。蒸発器の内容物は、急速蒸発され、臭素が濃縮された第1の液体(例えば、97%臭素回収)と、少量だけの臭素を含む第1の軽質ガス濃縮蒸気(N、CO)とを生ずる。第1の蒸気は、第2フラッシュ蒸発器に供給され、内容物が急速蒸発され、第2の臭素濃縮液体(そこで、例えば、追加の1.5%Brが回収される)と、第2熱交換器58を通過して次に第3フラッシュ蒸発器60に供給される第2の軽質ガス濃縮蒸気とを生ずる。第3フラッシュ蒸発器の内容物は、次に、急速蒸発され、例えば、追加の0.5%Br(液体)と、軽質ガスが非常に高濃縮された蒸気とを生ずる。蒸気のこの第3の流れにおいての極微量の臭素は、臭素スクラバー62において除去される。
所望される場合には、追加のフラッシュ蒸発器は、使用されることが可能である。実際問題として、しかし、それを越えて増加される資本要求及び運転費用がおそらく正当化されないであろう収穫逓減点(回収された追加の臭素量に関して)が存在する。
蒸留塔及びフラッシュ蒸発器の両方を用いる混合した設備は、使用されることが可能である。
一般に、臭素からの軽質ガスの分離について、ハロゲンと含まれる軽質ガスの沸点の差を考慮して、各フラッシュ蒸発器は、−60℃〜40℃、より好ましくは−20℃〜10℃の温度、及び、0.1〜50バール、より好ましくは5〜20バールの圧力で運転される。一〜三の急速蒸発がむしろ好まれる。圧力は、急速蒸発において変化することが可能であり、しかし、費用を減少するために、急速蒸発を系圧力で操作して費用のかかる圧縮を避けることが望ましい。急速蒸発を操作する温度は、圧力に依存している。例えば、高圧運転は、適度に高温でも良好な臭素分離を許容することが可能である。しかし、より低圧について、冷媒が、フラッシュ装置を冷却するために必要とされる可能性がある。直列気−液急速蒸発は、一以上の急速蒸発を構成することが可能である。
この発明の重要な側面は、主として軽質ガスからなる非常に希薄なガス流れから臭素または塩素)を化学的にガス洗浄する方法である。本方法は、ハロゲンを収着することができるハロゲン掃去剤を使用する。好ましくは、掃去剤は、希釈ガス流れから臭素蒸気を吸収し、次に、可逆的に、遊離臭素としてそれを定量的に再び放出することが可能である。臭素の吸着は、室温または高温で発生することが可能である。
一般に、臭素と反応して加熱でそれを放出することができるどんな物質も、臭素掃去剤として使用されることが可能である。ハロゲン掃去剤として使用に好適であると考えられる物質の限定的でない例としては、単独でまたは組み合わせて使用される、CuBr、CuCl、FeBr、FeCl、AuCl、AuBr、InBr、InCl、FeO、CuO、HgBr、Cu、Ag、Au、Hg、Pt、Pd、Ru、Rh、Fe、Os、及び、Irが挙げられる。現在、CuBrがむしろ好まれる。高表面積(担体に関する)を有する臭化銅が使用される場合に、臭化銅の全量が随分小さくても、随分高い活性が観測される。また、沈殿法により製造されたCuBrは、素材CuBrより良いことがわかった。
臭化銅(I)は、次の反応:2CuBr+Br→2CuBrによって、臭素と反応して臭化銅(II)を形成する。反応は、速く、完全であり、有利に、低温で起こる。反応は、表面結合されるようである。塊状CuBrを使用するときには、固体の近似的に1%が、漏出が起こる前に使用される。(CuBr及びCuBrの密度は、非常に似ており、表面は十分に更新しない;4.6対4.0g/cm)。CuBrとBr蒸気の反応は、気体と固体の反応であるので、反応速度は、固−気界面により限定され、そして、相応じて、表面積が高ければ、それだけ反応性が高い。それどころか、生CuBrの大結晶は、最少有効吸着剤である。漏出が起こるときには(Brは、もはや固体により保留されない)、消費されるCuBrの量は、全固体容積の近似的に0.2%であり、これは、固体の表面のみが反応に関係することを意味する。低い反応温度は、イオン移動の可能性、及び、残っている塊状CuBrの使用を退ける。
臭素分離から出てくる不活性ガス流れ(極微量の臭素を含む)は、低温または周囲温度であるので、CuBrの低温でBrを収着する能力は、部分的に有利であり、それゆえに、周囲温度または近傍でスクラバーを運転することは、少しも追加エネルギー入力を必要としない。
ガス洗浄された臭素は、固体(この場合には、臭化銅(II))を、それを250℃超過に、典型的には、250℃〜275℃に加熱することにより再生することによって、回収される。再生反応は、2CuBr(熱)→2CuBr+Brである。臭化銅が掃去剤である点で、再生は、熱により活性化され、酸素を必要としない。
ハロゲン掃去剤は、塊状粉末として使用されるかまたは担体に沈着されることが可能である。限定的でない例としては、シリカ、アルミナ、ジルコニア、チタニア、WO、CaO、MgO、Cr、及び、種々の炭化物、窒化物、並びに類似物質が挙げられる。第1の要求は、担体が5〜1500M/gの表面積を有することである。われわれの実験において、固体Cu(I)Br、もしくは、デーヴィーキャト(Davicat)SiZr4700またはデーヴィーキャト(Davicat)Si1151A(デーヴィッドソン・コーポレーション(Davidson Corporation))に沈着されたCu(I)Brを使用し、シリカは高表面積(近似的に300m/gを有する。Si4700Bは、略3重量%ZrOを含む。他の担体は、臭化銅上でガス洗浄反応を実行することにおいて、同等に有効である。
ハロゲン掃去剤、または支持体を加えた掃去剤は、充填塔反応器構成、または、殻及び管反応器のような他の構成において、利用されることが可能である。標準熱媒は、スクラバーの活性成分を再生温度にするために必要とされる熱を伝えるために使用されることが可能である。プロセス機構は、他方の反応器が再生を受ける間に一方がガス洗浄を受ける2つの反応器を含むことができる。
固体ガス洗浄剤は、不活性ガス流れから全臭素含有量を完全に保留することができる(スクラバーによる臭素減量は、1ppb未満であると推定された)。担持臭化銅(I)は、消耗及び再生の多サイクルの後に、再現性のある結果を示す。
担体(シリカのような)が使用されるときには、非均質表面は、より小さい微結晶の生成を起こし、感知できるより大きい表面積を有する核形成座を生ずる。担持物質が15重量%CuBrのみを含むところであっても、そのより高いCuBr表面積は、それを臭素蒸気保留に良い物質にする。
ハロゲン掃去剤としての臭化銅(I)の効率を調査するために、商業的に入手可能なCuBr、担持CuBr、及び、沈殿により形成されたCuBrを用いて、連続実験が行われた。原掃去剤(CuBr)は、CuBrを加熱することにより、再生された。結果は、表1において与えられる。
Figure 0005275817
注記:
%は、掃去剤により保留された全Br量である。
再生は、275℃において10〜15分以内で完全である。
数サイクルが、CuBr/4700Bの活性について減少することなく、試験された。
*−微量のAgBrが形成されたが、測定重量は、<10−4gである。
**−再生後にその効率は、商用材料の効率に減少した。
図6は、30分間、室温で、臭素/窒素流れに暴露された沈殿CuBrの試験管の写真である。暗物質は、CuBrである。加熱で、色は、CuBrの淡緑色に逆戻りし、臭素を放出する。
実験記録:30sccm/分Nは、0℃に冷却されたBrバブラーを通る1.5sccmNと混合された。固体吸着剤床は、1cmの直径を有する円筒ガラス管に入れられた。そのように生成された窒素中の希釈臭素への暴露時間は、室温において40分であった。スクラバー処理されたガスは、1MNaOHを含むトラップを通して泡立てられた。
担持CuBr物質の調製:担体は、略20重量%CuBr水中溶液に、溶液の色がほとんど無色になるまで、分散された。懸濁液は、濾過されて115℃で一晩中乾燥された。
再生:保留臭素の再生は、消耗後に固体ガス洗浄剤を有する反応器を275℃で20分間加熱することにより行われた。放出された臭素は、集められて、放出された臭素を1MNaOHトラップ溶液中で捕捉することにより定量化された。捕捉した臭素のほぼ完全に近い回収が可能である。
定量化:ガス洗浄剤により保留されないかまたは消耗したガス洗浄剤から再生された臭素の量は、終わりに、HNOで、pHが5以下に降下するまで酸性にされるNaOHトラップにおいての吸収により、続いて過剰0.5MAgNOを用いた(少しもさらなる沈殿が起こらないほど加えられる)AgBrの沈殿により、定量化された。存在する臭素量は、濾過してAgBrの沈殿をその重量が変化しないほど乾燥するために使用されるガラス濾過器の質量増加から計算された。
臭素漏出は、Br及びBrOのAgによる沈殿を用いることにより、測定され、ただし、NaOHトラップは、HNOで酸性まで、酸性化され;AgNoは、それ以上沈殿が形成しないほど加えられ;懸濁液は、40分間熟成することを許容され、次に乾燥予備秤量ガラス濾過器で濾過され、一定重量まで乾燥され、重量差は、AgBrである。
Figure 0005275817
AgBrの溶解度係数Kspは、5×10-13mol2-2である。AgNO溶液は、0.5M−3ml(またはより多くの)を合計略20〜25mlまで、酸性にされたNaOHトラップに加えられる。最終Ag濃度は、略0.06Mである。Br−の最小検出可能濃度は、略0.06ppbに該当する略8×10-12Mである。たとえ非理想状態が仮定されても(高い、イオン性、濃度、1よりほかの異なるイオン活量)、それでも、感度は、ppb範囲にある。
近似的に25容積%臭素を含む、40sccm(標準立方センチメートル/分)の流量の窒素の不活性ガス流れは、本実施形態において説明された方法によって、処理された。流れは、空冷熱交換器を使用することにより、工業的に、なし遂げることが可能である25℃の温度に冷却された。25バールの圧力である流れは、次に、5℃の温度で運転するただ1つの気液フラッシュ装置において急速蒸発される。急速蒸発からの流出口液体は、臭素流れに溶解された少しの不活性ガスと一緒に、臭素を原供給量の98%超過含む。不活性ガスと微量臭素を含む蒸気流れは、次に、担持された臭化銅(I)の床を室温で通り越した。不活性ガス流れからの臭素捕捉は、完全であり、ガス洗浄床は、40分の時間、完全な臭素捕捉を実行した。臭化銅(II)と臭化銅(I)を含む消耗したガス洗浄床は、275℃に加熱され、ほぼ完全に近い臭素回収が、15分の時間で観測された。
本発明は、ハロゲンを化学薬品生産のための供給原料または中間体として使用し、ハロゲン回収または精製が、不活性物質または軽質ガスの除去により改良される多数の工業プロセスにおいて有用性を認め、有効に減少された資本及び運転費用を生ずるであろう。これらの中に、米国特許第6486368号明細書、米国特許第6472572号明細書、米国特許第6472572号明細書、米国特許第6465696号明細書、米国特許第6462243号明細書、米国特許第6403840号明細書に記載されたアルコール、エーテル、オレフィン、及び、アルコキシ化物を製造する方法、「炭化水素供給原料を高級炭化水素及びオレフィンに転化する連続プロセス」(”Continuous Process for Converting Hydrocarbon Foodstocks into Higher Hydrocarbons and Olefins”)と題され(代理人事件登録書第56987/G506号)、これと同一の日に提出された米国特許出願に記載された高級炭化水素を製造する方法があり、その全内容がこの引用によりここで組み込まれる。例えば、天然ガスからガソリン種類炭化水素を製造する方法において、空気が再生に使用されるときには、窒素と二酸化炭素は、臭素化及び複分解区画へ繰り越す。未転化メタンを再循環するために、費用集約的である窒素のメタンからの分離が必要とされる。また、再生中に発生した二酸化炭素は、その両方が費用集約的である、圧力スイング吸着を用いるかまたはアミン主成分系を用いるかのいずれかで、未転化メタンから分離されなければならない。軽質ガスの臭素からの分離は、反応器寸法を減少するだけでなく、また生成物及び未転化反応体からの軽質ガスの分離を単純にする。ここで説明された分離方法は、臭素のようなハロゲンから軽質ガス(窒素と二酸化炭素を包含する)を分離する費用効果の高い過程を提供する。
本発明は、種々の実施形態及び実施例で説明されたが、これらに限定されない。他の変更、並びに添付の特許請求の範囲の均等物は、本発明の範囲内である。
本発明の1つの側面による、軽質ガスを臭素から分離するプロセスの略図である。 臭素生成(「臭素再生」)及び水吸着の追加要素を有する、図1に示されたプロセスの略図である。 本発明の他の側面による、3つのフラッシュ蒸発器の直列運転を利用する軽質ガスを臭素から分離するプロセスの略図である。 本発明の1つの側面による、天然ガスを高級炭化水素に転化し、工程中に形成された臭素を軽質ガスから分離する副プロセスを含む連続プロセスの略図である。 本発明の1つの実施形態において使用されるハロゲン掃去剤についてのハロゲン漏出を測定する実験方法の略図である。 本発明の1つの側面によって、臭素/窒素流れに暴露されたCuBr管の写真である。

Claims (10)

  1. 素から軽質ガスを分離する方法であって
    (a)臭素および1以上の軽質ガスの供給原料を蒸留塔またはフラッシュ蒸発器へ供給すること;
    (b)該蒸留塔またはフラッシュ蒸発器を操作して該供給原料を、(i)主量の臭素とほんの少量の軽質ガスとを含む第1の液体と、(ii)主量の軽質ガスとほんの少量の臭素とを含む第1の蒸気とに分離すること;及び、
    (c)該第1の蒸気を、固体の臭素掃去剤を含む化学スクラバーへ供給して臭素を該第1の蒸気から回収すること、を含む、方法。
  2. 該第1の液体を蒸留塔またはフラッシュ蒸発器へ供給して、該第1の液体を、(i)主量の臭素とほんの少量の軽質ガスとを含む第2の液体と、(ii)主量の軽質ガスとほんの少量の臭素とを含む第2の蒸気とに分離すること;及び、
    第2の蒸気を臭素掃去剤を含む化学スクラバーへ供給して臭素を該蒸気から回収すること、をさらに含む、請求項1に記載の方法。
  3. 該軽質ガスは、窒素を含む、請求項1に記載の方法。
  4. 該軽質ガスは、窒素と、二酸化炭素及びC〜C炭化水素からなる群から選択された以上の追加ガスとを含む、請求項1に記載の方法。
  5. 該化学スクラバーは、担持されたかまたは担持されていない臭素掃去剤の床を含む、請求項1に記載の方法。
  6. 臭素掃去剤は、CuBr、FeBr 、AuBr、InBr、FeO、CuO、HgBr、Cu、Ag、Au、Hg、Pt、Pd、Ru、Rh、Fe、Os、Ir、及びそれらの混合物からなる群から選択された物質を含む、請求項1に記載の方法。
  7. 臭素掃去剤は、CuBrを含む、請求項1に記載の方法。
  8. 臭素掃去剤は、金属酸化物、金属炭化物、金属窒化物、炭素、クレー、及びそれらの混合物からなる群から選択された物質に担持されている、請求項1に記載の方法。
  9. 臭素掃去剤は、Al、SiO、ZrO、TiO、WO、CaO、MgO、CrO、SiC、MoC、TiN、WN、炭素、ゼオライト、バーミキュライト、及びそれらの混合物からなる群から選択された物質に担持されている、請求項1に記載の方法。
  10. さらに、該化学スクラバーを加熱してそれから臭素を放出することを含む、請求項1に記載の方法。
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