WO2022069897A1 - Procédé d'épuration de déchets contenant des hydrocarbures - Google Patents

Procédé d'épuration de déchets contenant des hydrocarbures Download PDF

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Publication number
WO2022069897A1
WO2022069897A1 PCT/GB2021/052538 GB2021052538W WO2022069897A1 WO 2022069897 A1 WO2022069897 A1 WO 2022069897A1 GB 2021052538 W GB2021052538 W GB 2021052538W WO 2022069897 A1 WO2022069897 A1 WO 2022069897A1
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WO
WIPO (PCT)
Prior art keywords
waste material
process according
hydrocarbon
composition
water
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PCT/GB2021/052538
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English (en)
Inventor
John Hogg
Alfred Kelly
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Turbulentus Technology Limited
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Publication date
Application filed by Turbulentus Technology Limited filed Critical Turbulentus Technology Limited
Publication of WO2022069897A1 publication Critical patent/WO2022069897A1/fr

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    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09KMATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K8/00Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
    • C09K8/52Compositions for preventing, limiting or eliminating depositions, e.g. for cleaning
    • C09K8/524Compositions for preventing, limiting or eliminating depositions, e.g. for cleaning organic depositions, e.g. paraffins or asphaltenes
    • EFIXED CONSTRUCTIONS
    • E21EARTH OR ROCK DRILLING; MINING
    • E21BEARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B21/00Methods or apparatus for flushing boreholes, e.g. by use of exhaust air from motor
    • E21B21/06Arrangements for treating drilling fluids outside the borehole
    • E21B21/063Arrangements for treating drilling fluids outside the borehole by separating components
    • E21B21/065Separating solids from drilling fluids
    • E21B21/066Separating solids from drilling fluids with further treatment of the solids, e.g. for disposal

Definitions

  • the present disclosure relates to a process for cleaning hydrocarbon-containing waste, and to an apparatus for carrying out said process.
  • the drilling of a subterranean well typically involves pumping a drilling fluid (typically a water-in-oil emulsion) to a drilling location.
  • the drilling mud which contains the drilling fluid and drilling cuttings, is then brought back to surface.
  • a major challenge in the drilling industry is that the cuttings are contaminated with a significant amount of hydrocarbon compounds, including the oil from the drilling emulsion itself.
  • Treating the waste from this process can be vastly expensive and currently consists of two main approaches namely (a) transporting the waste material to a dedicated on-land facility (which is logistically burdensome and vastly expensive) or (b) performing on-site thermal treatment of the waste material.
  • On-site thermal treatments can occupy a large proportion of very limited space on drilling platforms and may represent health and safety risks.
  • US2014367501 (A1 ) describes a system for treating drill cuttings.
  • the system includes a first stage that receives the drill cuttings and generates a first drill cuttings slurry and a second stage that receives the first drill cuttings slurry and generates solids.
  • the first stage may include a mixer receiving at least one additive from at least one treatment fluid supply. The mixer mixes the at least one additive with the drill cuttings to form a drill cuttings mixture and reduces the drill cuttings to a predetermined size.
  • the first stage also includes a separator receiving the drill cutting mixture. The separator separates liquids from solids in the drill cuttings mixture to form the first drill cuttings slurry.
  • the second stage may include a mixer that mixes a cleaning fluid from a second treatment fluid supply with the drill cuttings to form a second drill cuttings mixture.
  • the second stage may also include a separator receiving the second drill cutting mixture. The separator separates liquids from solids in the drill cuttings mixture to form the solids stream and the liquids stream.
  • US5195847 describes a process for recovering hydrocarbon contaminants from a drilling mud by adding a hydrocarbon diluent along with a wash water to create an emulsion. The wash water having a surfactant dissolved therein.
  • the resultant emulsion is subjected to centrifugation which produces three distinct layers that can be easily separated to produce a clean drilling mud, a clear wash water, and a hydrocarbon phase containing the hydrocarbon contaminant and the hydrocarbon diluent.
  • US2016102239 (A1 ) describes the use of mesophase surfactant solutions and/or micellar solutions, and/or pre-formed single phase microemulsions (SPMEs), and in situ-formed fluids to clean up and remove hydrocarbons and synthetic oils such as oilbased mud filter cake and near wellbore damage in oil and gas wells. Removal occurs by solubilization of the hydrocarbons and synthetic oils into the micellar solutions, SPME, in situ-formed fluids, etc. when the fluid formulation contacts the hydrocarbons and synthetic oils.
  • SPME single phase microemulsions
  • CN 108467797 discloses a microemulsion, a preparation method and application thereof and a treatment method of oil-containing drill cuttings.
  • the microemulsion comprises 15 to 25% by weight of an ionic surfactant, 5 to 20% by weight of a cosurfactant, 1 to 2.5% by weight of sodium chloride, 5 to 10% by weight of an oil phase and 55 to 65% by weight of water.
  • the ionic surfactant is selected from at least one of sodium lauryl ether sulfate, fatty alcohol polyoxyethylene ether sulfate, and sodium lauryl sulfate; and the co-surfactant is at least one selected from the group consisting of butyl lactate, butyl acetate, propyl acetate, and amyl propionate.
  • US5156686 discloses a method in which drill cuttings are cleaned of oilbased drilling mud and oil using a cleaning agent, such as a C6-C10 carboxylic acid, that is preferentially oil soluble at one pH and preferentially water soluble at another pH.
  • a cleaning agent such as a C6-C10 carboxylic acid
  • the oily cuttings are treated with the carboxylic acid and then washed with an aqueous, alkaline washing solution, which converts the carboxylic acid to its water soluble salt and, with vigorous agitation, lifts oil from the cutting.
  • a process for cleaning a waste material may comprise a first step comprising mixing a first composition with the waste material; and a second step comprising adding a second composition to the mixture.
  • the waste material may be or may comprise a hydrocarbon-containing or hydrocarbon-contaminated waste material.
  • the amount of hydrocarbon in the waste material may be at equal to or greater than about 2 wt%, typically equal to or greater than about 5 wt%, typically in the range of about 2 wt% to 10 wt %.
  • the first composition may comprise, may consist essentially of, or may consist of at least one surfactant.
  • the first composition may comprise or may be an aqueous composition.
  • the first composition may comprise, may consist essentially of or may consist of water and at least one surfactant.
  • the second composition may comprise, may consist essentially of, or may consist of an electrolyte or a salt.
  • the second composition e.g. the electrolyte or a salt, may be provided in solid form.
  • the second composition may be provided as a solution, e.g. as an aqueous solution.
  • the second composition e.g. the electrolyte or a salt, may be provided in as a concentrated or saturated aqueous solution of the electrolyte or salt.
  • the first step and the second step may be carried out sequentially.
  • the second step may follow the first step.
  • the at least one surfactant may encapsulate at least some hydrocarbons, e.g. at least some of the hydrocarbons from the waste material, in particles such as micelles.
  • the addition of the electrolyte or the salt in the second step may increase the hardness of the aqueous phase and may cause phase separation or precipitation of the hydrocarbon-trapping particles, e.g. micelles. This may allow the hydrocarbon-trapping particles, e.g. micelles to be separated from the mixture.
  • the addition of the electrolyte or the salt may facilitate the separation of the hydrocarbon-trapping particles, e.g. micelles from the aqueous phase.
  • the waste material e.g. the hydrocarbon-contaminated waste material
  • the process may comprise separating the waste material into three phases: solids (where solids are originally present in the waste), an aqueous phase and a hydrocarbon-containing micelle layer.
  • the solids phase and the aqueous phase may be substantially free of hydrocarbons.
  • the waste material e.g. the hydrocarbon-contaminated waste material
  • the waste material may comprise a liquid-based, e.g. an aqueous based, waste material.
  • the process may comprise separating the waste material into two phases: an aqueous phase and a hydrocarbon micelle layer.
  • the aqueous phase may be substantially free of hydrocarbons.
  • substantially free of hydrocarbons will be herein understood to mean that the amount of hydrocarbons remaining in the waste material may be equal to or less than about 250 ppm, e.g. equal to or less than about 50 ppm, e.g. equal to or less than about 5ppm and/or may mean that the amount of hydrocarbons remaining in the aqueous phase may be equal to or less than about 250 mg/L, e.g. equal to or less than about 50mg/L, e.g. equal to or less than about 5 mg/L.
  • the waste material e.g. the hydrocarbon-contaminated waste material
  • the waste material may be generated from the exploration of and recovery of hydrocarbons, for example from wellbores, and may comprise or may be drilling mud, drilling cuttings, fluid from water injection processes, or the like.
  • the cleaning process may be an effective way in which to treat hydrocarbon-contaminated waste by allowing separation and removal of the hydrocarbons from the waste. This may allow the separated waste streams to be disposed of safely and in line with local safety and environmental regulations.
  • the process may remove all or substantially all hydrocarbons from both the drilling cuttings, and from any associated water phase. Both the drilling cuttings and the water phase may be returned to the sea, or disposed of according to local regulations. The hydrocarbon phase may be recycled, for example into drilling fluid.
  • the surfactant may comprise, may consist essentially of or may consist of a soapbased surfactant.
  • the surfactant may comprise, may consist essentially of, or may consist of a fatty acid carboxylate, for example an oleate salt.
  • the surfactant may be sodium oleate, sodium tallowate or potassium oleate.
  • Sodium oleate or sodium tallowate may provide effective separation, e.g. 100% separation (or substantially 100% separation), of hydrocarbons from the aqueous phase (and solids phase if present).
  • the quantity of surfactant may be in the range of about 1 to 5% by weight based on the initial weight of the hydrocarbon-contaminated waste.
  • the surfactant ratio may be in the range of about 1 to 5% by weight of the cuttings.
  • surfactants having a higher content of saturated hydrocarbons may be less effective at cleaning the waste material in the process.
  • sodium oleate is mono-saturated and may be provide superior cleaning.
  • castile soap which may comprise a larger level of saturated hydrocarbons may not as effectively separate the hydrocarbons from the waste materials.
  • the base components, e.g. a salt and an acid, of the surfactant may be added to the mixture in the first step.
  • the surfactant may be generated in situ by adding surfactant starting materials are reacting the surfactant starting materials in situ.
  • the surfactant selected for use in the process is sodium oleate
  • the process may comprise mixing and/or reacting sodium hydroxide and oleic acid during the first step of the process.
  • the surfactant is potassium oleate
  • the process may comprise mixing and/or reacting potassium hydroxide and oleic acid during the first step of the process.
  • the electrolyte or the salt may comprise any composition, for example a salt, suitable for increasing water hardness.
  • the salt may comprise an inorganic salt such as sodium chloride.
  • the amount of salt required may vary, for example depending on the initial hardness of the water.
  • the quantity of salt required may be in the range of about 2 to 5% by weight based on the initial weight of the hydrocarbon-contaminated waste.
  • the waste material may comprise solids, or may be in solid form.
  • the first step may comprise washing the waste material in potable water.
  • the quantity of potable water may equal the quantity of waste material by weight.
  • the process may further comprise adding a water softener to the mixture, e.g. during the first step.
  • the addition of the water softener may allow the surfactant to form micelles with the hydrocarbons, regardless of initial water hardness/softness.
  • the addition of the water softener may allow the first step of the process to be effective even when the water added is particularly hard (which could otherwise affect performance).
  • the water softener may comprise, for example, sodium tripolyphosphate.
  • the process may be performed in any suitable mixing vessel.
  • the mixing vessel may comprise a vertical, cylindrical tank having a central shaft for driving mixing blade.
  • the mixing vessel may comprise a horizontal, cylindrical tank.
  • Paddles may be provided inside the tank.
  • the horizontal tank may be rotated to provide agitation.
  • a horizontal mixing vessel may improve the initial wetting of the contaminated waste.
  • the mixing vessel may comprise a vertical cylinder having a compressed air mixing system.
  • the components within the cylinder may be agitated by injection, e.g. bursts, of compressed air.
  • the first step may comprise mixing the waste material and the first composition for approximately 15 minutes.
  • the first step may comprise mixing the waste material and the first composition for at least 15 minutes.
  • the mixing may comprise agitating the waste material and the first composition together within the mixing vessel.
  • the mixture may be agitated for at least a further 5 minutes, e.g. at least a further 10 minutes.
  • the process may comprise a third step.
  • the third step may comprise allowing the mixture to settle out into different phases.
  • the third step may follow the second step.
  • the settling may occur under gravity.
  • the process may comprise discharging the mixture to a settling tank.
  • the settling process may last for approximately 30 to 60 minutes. Subsequently, the hydrocarbon phase may be skimmed from the mixture.
  • the speed in which the settling process, and the process as a whole, occurs may be advantageous within a commercial setting. Providing a process which may allow for the effective cleaning of hydrocarbons from the waste material and aqueous phase in for, example, less than one hour may allow for the process to be applied in a variety of industrial settings.
  • the hydrocarbon phase may be recycled.
  • the aqueous phase may comprise no more than 250 mg/L or 250 ppm, e.g. no more than 50 mg/L or 50 ppm, e.g. no more than 5 mg/L or 5 ppm, hydrocarbon and as such, may be discharged directly to the sea or disposed of according to local recommendations.
  • Any solids phase present in the mixture may comprise no more than 250ppm, e.g. no more than 50ppm, e.g. no more than 5 ppm, hydrocarbon, and as such, may be discharged directly to the sea or disposed of according to local recommendations.
  • the aqueous phase may be recycled for use in the first step of the process. This may reduce the demand for fresh potable water in the process and may be particularly advantageous when the process is used offshore where there is a limited supply of potable water.
  • the surfactant may be recycled for use in the first step of the process.
  • the aqueous phase may comprise a recycled or part recycled aqueous phase.
  • the recycled aqueous phase may comprise the recycled surfactant. This may reduce the amount of surfactant required to operate the process repeatedly, which may be particularly advantageous to offshore processing where space is limited, and may also reduce cost and environmental impact.
  • the process may be a batch process, wherein fresh or recycled quantities of the first and second compositions are mixed with quantities of waste material.
  • the process may comprise a hybrid continuous batch process, wherein after the setting stage, the hydrocarbon phase may be removed from the mixing vessel and new quantities of waste material may be added to the mixing vessel.
  • the process may comprise physically removing the solids (where solids are present).
  • the process may comprise filtering the solids from the liquid, e.g. aqueous, phase.
  • an apparatus for performing cleaning of hydrocarbon-contaminated waste may comprise a mixing vessel and an agitation means.
  • the mixing vessel may be configured to be rotated, e.g. on a horizontal axis.
  • the agitation means may comprise paddles located within the mixing vessel.
  • the mixing vessel may be configured to rotate on a vertical axis.
  • the agitation means may comprise compressed air.
  • Figure 1 illustrates hydrocarbon-contaminated drill cuttings mixed with water and the first composition in a mixing vessel
  • Figure 2 shows the mixture of Figure 1 after the clearing process has been applied, and which has settled into three phases to allow for separation
  • Figure 3 shows a mixture of contaminated drilling cuttings shortly after application of the cleaning process
  • Figure 4 shows a separated mixture of cleaned drill cuttings after application of the cleaning process using sodium oleate as the surfactant; and Figure 5 shows cleaned heavy wax from a contaminated flow line after application of the cleaning process using sodium oleate.
  • equal quantities by weight of drilling cuttings and water are mixed in a mixing vessel 10 with a first composition.
  • the first composition comprises. 1 to 5% w/w of the first composition to the initial weight of the drilling cuttings is mixed with the waste material.
  • the first composition comprises a surfactant, preferably a fatty acid carboxylate such as sodium oleate, sodium tallowate, or potassium oleate.
  • the resulting mixture 12 is agitated for approximately 15 minutes to allow for sufficient wetting and the formation of hydrocarbon encapsulating micelles.
  • a water softener for example, sodium tripolyphosphate
  • the amount of water softener, if water softener is used, will be dependent upon the hardness of the potable water used in the process.
  • a second composition to the initial weight of the drilling cuttings is added to the mixing vessel 10.
  • the second composition comprises sodium chloride.
  • the mixture is agitated for a further 5 to 10 minutes.
  • the addition of the salt in the second step increases the hardness of the aqueous phase and causes precipitation of the hydrocarbon-trapping micelles. This may allow the hydrocarbon- trapping micelles to be separated from the mixture.
  • the mixtures can then be discharged to a settling tank 20 where the mixture is allowed to separate under gravity into three phases. Alternatively, the settling may take place in the mixing vessel. This step can take between 30 to 60 minutes.
  • the mixture separates into a layer of substantially hydrocarbon -free drill cuttings 18, a substantially hydrocarbon-free aqueous phase 16, and a hydrocarbon phase 14.
  • the hydrocarbon phase 14 can be skimmed off for reuse, if desired.
  • the drill cuttings 18 and the aqueous phase 16 may be disposed of according to local regulations, for example into the sea when the process is utilised on an offshore facility.
  • the aqueous phase may be recycled for use in the first step of the process.
  • the resulting aqueous phase may comprise sufficient quantities of surfactant that in the first step, no further surfactant needs to be added, or a reduced quantity is required. Recycling the aqueous phase and surfactant in this manner may reduce the demand for fresh potable water and surfactants. This may be advantageous, particularly, when the process is used offshore where space is limited.
  • FIGs 3 and 4 show the application of the process to hydrocarbon contaminated drilling cuttings using sodium oleate as a surfactant.
  • a hydrocarbon phase 14 an aqueous phase 16 (also comprising a blue dye in this example) and a solids phase 18.
  • the three phases can be separated further as illustrated in Figure 4.
  • Figure 5 shows an image cleaned heavy wax 24 from a contaminated flow line after application of the cleaning process using sodium oleate. A distinct hydrocarbon layer 24 can be seen in the sample.
  • the top layer was hydrocarbons.
  • the middle layer was water.
  • the bottom layer was solids
  • the water and solids were tested using Oil Test Papers (Machinery-Nangel type 907 60) and found to contain zero hydrocarbons. The hydrocarbon layer was harvested.
  • the total contents of the mixing vessel was the decanted to a glass settlement vessel.
  • the top layer was hydrocarbons.
  • the middle layer was water.
  • the bottom layer was solids
  • the water and solids were tested using Oil Test Papers (Machinery-Nangel type 907 60) and found to contain zero hydrocarbons. The hydrocarbon layer was harvested.
  • the total contents of the mixing vessel was the decanted to a glass settlement vessel.
  • the top layer was hydrocarbons.
  • the middle layer was water.
  • the bottom layer was solids
  • the water and solids were tested using Oil Test Papers (Machinery-Nangel type 907 60) and found to contain zero hydrocarbons. The hydrocarbon layer was harvested.
  • the total contents of the mixing vessel was the decanted to a glass settlement vessel.
  • the top layer was hydrocarbons.
  • the middle layer was water.
  • the bottom layer was solids
  • the total contents of the mixing vessel was the decanted to a glass settlement vessel.
  • the top layer was hydrocarbons.
  • the middle layer was water.
  • the bottom layer was solids
  • the water and solids were tested using Oil Test Papers (Machinery-Nangel type 907 60) and found to contain zero hydrocarbons. The hydrocarbon layer was harvested.
  • Neodol 23 a blend of synthetic alcohols and ethoxylates
  • the total contents of the mixing vessel was the decanted to a glass settlement vessel.

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Mining & Mineral Resources (AREA)
  • Geology (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Environmental & Geological Engineering (AREA)
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  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Detergent Compositions (AREA)

Abstract

L'invention concerne un procédé d'épuration de déchets. Le procédé comprend une première étape consistant à mélanger une première composition avec les déchets (12), les déchets comprenant des déchets contenant des hydrocarbures, et la première composition comprenant un tensioactif ; et une seconde étape consistant à ajouter une seconde composition au mélange de la première composition et des déchets (12), la seconde composition comprenant un électrolyte ou un sel. La deuxième étape suit la première étape.
PCT/GB2021/052538 2020-10-01 2021-10-01 Procédé d'épuration de déchets contenant des hydrocarbures WO2022069897A1 (fr)

Applications Claiming Priority (2)

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GB2015615.4 2020-10-01
GBGB2015615.4A GB202015615D0 (en) 2020-10-01 2020-10-01 Process for cleaning hydrocarbon-containing waste

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WO2022069897A1 true WO2022069897A1 (fr) 2022-04-07

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Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2810558A (en) * 1955-02-25 1957-10-22 Stothert & Pitt Ltd Concrete mixers
US5156686A (en) 1990-11-30 1992-10-20 Union Oil Company Of California Separation of oils from solids
US5195847A (en) 1992-01-15 1993-03-23 Guymon E Park Process for cleaning drilling mud contaminated with hydrocarbons
US20070056611A1 (en) * 2003-09-09 2007-03-15 Martin Andrew J Waste solid cleaning
US20120181085A1 (en) * 2011-01-14 2012-07-19 Baker Hughes Incorporated Method for cleaning drill cuttings
US20140367501A1 (en) 2013-06-13 2014-12-18 Baker Hughes Incorporated Systems and methods to remove hydrocarbon oils from contaminated drill cuttings
US20160102239A1 (en) 2014-10-14 2016-04-14 Baker Hughes Incorporated Microemulsions, mesophase surfactant and micellar solutions, and in situ-formed fluids formulated with high density brine
CN108467797A (zh) 2018-03-28 2018-08-31 中国石油大学(华东) 微乳液及其制备方法和应用及含油钻屑的处理方法

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2810558A (en) * 1955-02-25 1957-10-22 Stothert & Pitt Ltd Concrete mixers
US5156686A (en) 1990-11-30 1992-10-20 Union Oil Company Of California Separation of oils from solids
US5195847A (en) 1992-01-15 1993-03-23 Guymon E Park Process for cleaning drilling mud contaminated with hydrocarbons
US20070056611A1 (en) * 2003-09-09 2007-03-15 Martin Andrew J Waste solid cleaning
US20120181085A1 (en) * 2011-01-14 2012-07-19 Baker Hughes Incorporated Method for cleaning drill cuttings
US20140367501A1 (en) 2013-06-13 2014-12-18 Baker Hughes Incorporated Systems and methods to remove hydrocarbon oils from contaminated drill cuttings
US20160102239A1 (en) 2014-10-14 2016-04-14 Baker Hughes Incorporated Microemulsions, mesophase surfactant and micellar solutions, and in situ-formed fluids formulated with high density brine
CN108467797A (zh) 2018-03-28 2018-08-31 中国石油大学(华东) 微乳液及其制备方法和应用及含油钻屑的处理方法

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