82:, where the mixture is added to the unit at the start of the distillation, distillate fractions are taken out sequentially in time (one after another) during the distillation, and the remaining bottoms fraction is removed at the end. Because each of the distillate fractions are taken out at different times, only one distillate exit point (location) is needed for a batch distillation and the distillate can just be switched to a different receiver, a fraction-collecting container. Batch distillation is often used when smaller quantities are distilled. In a continuous distillation, each of the fraction streams is taken simultaneously throughout operation; therefore, a separate exit point is needed for each fraction. In practice when there are multiple distillate fractions, the distillate exit points are located at different heights on a
392:
condensation of the upflowing vapors, thereby increasing the efficacy of the distillation tower. The more reflux that is provided, the better is the tower's separation of the lower boiling from the higher boiling components of the feed. A balance of heating with a reboiler at the bottom of a column and cooling by condensed reflux at the top of the column maintains a temperature gradient (or gradual temperature difference) along the height of the column to provide good conditions for fractionating the feed mixture. Reflux flows at the middle of the tower are called pumparounds.
196:
1201:
20:
492:(HETP) will be greater than expected. The problem is not the packing itself but the mal-distribution of the fluids entering the packed bed. Liquid mal-distribution is more frequently the problem than vapor. The design of the liquid distributors used to introduce the feed and reflux to a packed bed is critical to making the packing perform at maximum efficiency. Methods of evaluating the effectiveness of a liquid distributor can be found in references.
252:, pressures, and compositions at every point (location). Unless the process is disturbed due to changes in feed, heating, ambient temperature, or condensing, steady state is normally maintained. This is also the main attraction of continuous distillation, apart from the minimum amount of (easily instrumentable) surveillance; if the feed rate and feed composition are kept constant, product rate and
423:. Such devices are commonly known as "plates" or "trays". Each of these plates or trays is at a different temperature and pressure. The stage at the tower bottom has the highest pressure and temperature. Progressing upwards in the tower, the pressure and temperature decreases for each succeeding stage. The
643:
cut with a boiling range from about 180 °C to about 315 °C. The boiling ranges between any cut and the next cut overlap because the distillation separations are not perfectly sharp. After these come the heavy fuel oil cuts and finally the bottoms product, with very wide boiling ranges. All
487:
required to make a given separation is calculated using a specific vapor to liquid ratio. If the liquid and vapor are not evenly distributed across the superficial tower area as it enters the packed bed, the liquid to vapor ratio will not be correct in the packed bed and the required separation will
475:
takes place. Unlike conventional tray distillation in which every tray represents a separate point of vapor–liquid equilibrium, the vapor–liquid equilibrium curve in a packed column is continuous. However, when modeling packed columns it is useful to compute a number of theoretical plates to denote
211:
This is what happens in a continuous distillation column. A mixture is heated up, and routed into the distillation column. On entering the column, the feed starts flowing down but part of it, the component(s) with lower boiling point(s), vaporizes and rises. However, as it rises, it cools and while
435:
If each physical tray or plate were 100% efficient, then the number of physical trays needed for a given separation would equal the number of equilibrium stages or theoretical plates. However, that is very seldom the case. Hence, a distillation column needs more plates than the required number of
263:
Since a continuous distillation unit is fed constantly with a feed mixture and not filled all at once like a batch distillation, a continuous distillation unit does not need a sizable distillation pot, vessel, or reservoir for a batch fill. Instead, the mixture can be fed directly into the column,
427:
for each feed component in the tower reacts in its unique way to the different pressure and temperature conditions at each of the stages. That means that each component establishes a different concentration in the vapor and liquid phases at each of the stages, and this results in the separation of
391:
to achieve more efficient separation of products. Reflux refers to the portion of the condensed overhead liquid product from a distillation tower that is returned to the upper part of the tower as shown in images 3 and 4. Inside the tower, the downflowing reflux liquid provides cooling and partial
633:
The naphtha cut, as that fraction is called, contains many different hydrocarbon compounds. Therefore, it has an initial boiling point of about 35 °C and a final boiling point of about 200 °C. Each cut produced in the fractionating columns has a different boiling range. At some distance
180:
Industrial distillation is typically performed in large, vertical cylindrical columns (as shown in images 1 and 2) known as "distillation towers" or "distillation columns" with diameters ranging from about 65 centimeters to 11 meters and heights ranging from about 6 meters to 60 meters or more.
395:
Changing the reflux (in combination with changes in feed and product withdrawal) can also be used to improve the separation properties of a continuous distillation column while in operation (in contrast to adding plates or trays, or changing the packing, which would, at a minimum, require quite
219:
Image 3 depicts a simple continuous fractional distillation tower for separating a feed stream into two fractions, an overhead distillate product and a bottoms product. The "lightest" products (those with the lowest boiling point or highest volatility) exit from the top of the columns and the
356:
Although small size units, mostly made of glass, can be used in laboratories, industrial units are large, vertical, steel vessels (see images 1 and 2) known as "distillation towers" or "distillation columns". To improve the separation, the tower is normally provided inside with horizontal
101:
or a similar feedstock, each fraction contains many components of similar volatility and other properties. Although it is possible to run a small-scale or laboratory continuous distillation, most often continuous distillation is used in a large-scale industrial process.
513:). In those cases, if the distillate product is insoluble in water, the reflux drum may contain a condensed liquid distillate phase, a condensed water phase and a non-condensible gas phase, which makes it necessary that the reflux drum also have a water outlet stream.
203:
The principle for continuous distillation is the same as for normal distillation: when a liquid mixture is heated so that it boils, the composition of the vapor above the liquid differs from the liquid composition. If this vapor is then separated and
303:
models are used both for design and subsequently in operation of the column as well. Modeling is also used to optimize already erected columns for the distillation of mixtures other than those the distillation equipment was originally designed for.
508:
outlet stream. In yet other cases, the overhead stream may also contain water vapor because either the feed stream contains some water or some steam is injected into the distillation tower (which is the case in the crude oil distillation towers in
319:
The column can be fed in different ways. If the feed is from a source at a pressure higher than the distillation column pressure, it is simply piped into the column. Otherwise, the feed is pumped or compressed into the column. The feed may be a
521:
Beside fractional distillation, that is mainly used for crude oil refining, multicomponent mixtures are usually processed in order to purify their single components by means of a series of distillation columns, i.e. the distillation train.
243:
or approximate steady state. Steady state means that quantities related to the process do not change as time passes during operation. Such constant quantities include feed input rate, output stream rates, heating and cooling rates,
638:
cut. The boiling range of that cut is from an initial boiling point of about 150 °C to a final boiling point of about 270 °C, and it also contains many different hydrocarbons. The next cut further down the tower is the
476:
the separation efficiency of the packed column with respect to more traditional trays. Differently shaped packings have different surface areas and void space between packings. Both of these factors affect packing performance.
542:
unit is most common process-intensifying unit related to distillation. In particular, it is the arrangement in a single column shell of the
Petlyuk configuration that has been proved to be thermodynamically equivalent.
452:), beneficial when operating under vacuum. If a distillation tower uses packing instead of trays, the number of necessary theoretical equilibrium stages is first determined and then the packing height equivalent to a
199:
Image 3: Chemical engineering schematic of
Continuous Binary Fractional Distillation tower. A binary distillation separates a feed mixture stream into two fractions: one distillate and one bottoms fractions.
115:
500:
Images 4 and 5 assume an overhead stream that is totally condensed into a liquid product using water or air-cooling. However, in many cases, the tower overhead is not easily condensed totally and the
349:
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with a packing material. To provide the heat required for the vaporization involved in distillation and also to compensate for heat loss, heat is most often added to the bottom of the column by a
336:. If the feed is a liquid at a much higher pressure than the column pressure and flows through a pressure let-down valve just ahead of the column, it will immediately expand and undergo a partial
45:, is an ongoing separation in which a mixture is continuously (without interruption) fed into the process and separated fractions are removed continuously as output streams. Distillation is the
220:"heaviest" products (the bottoms, those with the highest boiling point) exit from the bottom of the column. The overhead stream may be cooled and condensed using a water-cooled or air-cooled
157:
feedstock is a very complex multicomponent mixture that must be separated and yields of pure chemical compounds are not expected, only groups of compounds within a relatively small range of
602:
does not produce products having a single boiling point; rather, it produces fractions having boiling ranges. For example, the crude oil fractionator produces an overhead fraction called "
405:
28:
986:
Madenoor
Ramapriya, Gautham; Tawarmalani, Mohit; Agrawal, Rakesh (August 2014). "Thermal coupling links to liquid-only transfer streams: A path for new dividing wall columns".
352:
Image 4: Simplified chemical engineering schematic of
Continuous Fractional Distillation tower separating one feed mixture stream into four distillate and one bottoms fractions
264:
where the actual separation occurs. The height of the feed point along the column can vary on the situation and is designed so as to provide optimal results. See
530:
A distillation train is defined by a sequence of distillation columns arranged in series or in parallel whose aim is the multicomponent mixtures purification.
291:
Design and operation of a distillation column depends on the feed and desired products. Given a simple, binary component feed, analytical methods such as the
118:. Continuous distillation is used widely in the chemical process industries where large quantities of liquids have to be distilled. Such industries are the
782:
379:. Depending on their purpose, distillation columns may have liquid outlets at intervals up the length of the column as shown in image 4.
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860:
177:. It is often not worthwhile separating the components in these fractions any further based on product requirements and economics.
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and column distillation the concentrate would be damaged from the long residence times and high temperatures that must be applied.
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Distillation towers (such as in images 3 and 4) use various vapor and liquid contacting methods to provide the required number of
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below the overhead, the next cut is withdrawn from the side of the column and it is usually the jet fuel cut, also known as a
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the components. Some example trays are depicted in image 5. A more detailed, expanded image of two trays can be seen in the
67:
distillate fraction, which has boiled and been separately captured as a vapor condensed to a liquid, and practically always a
460:(HETP), is also determined. The total packing height required is the number of theoretical stages multiplied by the HETP.
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When a continuous distillation column is in operation, it has to be closely monitored for changes in feed composition,
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86:. The bottoms fraction can be taken from the bottom of the distillation column or unit, but is often taken from a
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75:) fraction, which is the least volatile residue that has not been separately captured as a condensed vapor.
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Another factor in addition to the packing shape and surface area that affects the performance of random or
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instead of trays. These offer the advantage of a lower pressure drop across the column (when compared to
471:. Liquids tend to wet the surface of the packing and the vapors pass across this wetted surface, where
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and product composition. Many of these tasks are performed using advanced computer control equipment.
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Random
Packing, Vapor and Liquid Distribution: Liquid and gas distribution in commercial packed towers
221:
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methods are commonly able to gradually return the continuous process to another steady state again.
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265:
939:, Moore, F., Rukovena, F., Chemical Plants & Processing, Edition Europe, August 1987, p. 11-15
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Image 5: Cross-sectional diagram of a binary fractional distillation tower with bubble-cap trays.
208:
into a liquid, it becomes richer in the lower boiling point component(s) of the original mixture.
1307:
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by Ivar J. Halvorsen and Sigurd
Skogestad, Norwegian University of Science and Technology, Norway
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61:. The process produces at least two output fractions. These fractions include at least one
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83:
949:
Structured
Packing, Liquid Distribution: A new method to assess liquid distributor quality
8:
1327:
801:
734:. Vol. 8 (5th ed.). Hoboken, New Jersey: Wiley-Interscience. pp. 739–785.
276:
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or partial separation of a liquid feed mixture into components or fractions by selective
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606:" which becomes a gasoline component after it is further processed through a catalytic
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can be improved by recycling some of the externally condensed top product liquid as
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can be used to assist in the design. For a multi-component feed, computerized
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Another way of improving the separation in a distillation column is to use a
123:
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963:
Advanced distillation technologies : design, control, and applications
885:
Beychok, Milton (May 1951). "Algebraic
Solution of McCabe-Thiele Diagram".
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42:
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951:, Spiegel, L., Chemical Engineering and Processing 45 (2006), p. 1011-1017
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resulting in a liquid-vapor mixture as it enters the distillation column.
149:
separation and similar industries, but it finds its widest application in
595:, they are formed in many of the processes used in a petroleum refinery.
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not be achieved. The packing will appear to not be working properly. The
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is liquid and vapor distribution entering the packed bed. The number of
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19:
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are also constant. Even when a variation in conditions occurs, modern
135:
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article. The reboiler often acts as an additional equilibrium stage.
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568:
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154:
98:
985:
660:(BHO). Short path distillation is a popular method due to the short
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these cuts are processed further in subsequent refining processes.
635:
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332:(i.e., liquid at its boiling point at the column's pressure), or a
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part of it continues up as vapor, some of it (enriched in the less
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This packing material can either be random dumped packing such as
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Each fraction may contain one or more components (types of
31:
Image 2: A crude oil vacuum distillation column as used in
1096:
by Prof. Randall M. Price at
Christian Brothers University
1105:
505:
1015:
551:
730:
Kroschwitz, Jacqueline I.; Seidel, Arza, eds. (2004).
239:
In a continuous distillation, the system is kept in a
533:
1340:
798:
729:
648:Continuous distillation of cannabis concentrates
591:. Although crude oils generally do not contain
387:Large-scale industrial fractionation towers use
328:, a partially vaporized liquid-vapor mixture, a
755:McCabe, W., Smith, J. and Harriott, P. (2004).
732:Kirk-Othmer Encyclopedia of Chemical Technology
495:
23:Image 1: Typical industrial distillation towers
925:Photographs of bubble cap and other tray types
516:
1126:
436:theoretical vapor–liquid equilibrium stages.
78:An alternative to continuous distillation is
1040:
781:: CS1 maint: multiple names: authors list (
1018:Petroleum Refining Technology and Economics
893:
1133:
1119:
825:
626:into more complex molecules with a higher
954:
900:Seader, J. D.; Henley, Ernest J. (1998).
559:crude oils contain hundreds of different
116:chemical engineering and food engineering
105:
858:Perry, Robert H.; Green, Don W. (1984).
794:
792:
490:height equivalent to a theoretical plate
458:height equivalent to a theoretical plate
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228:may be a steam-heated or hot oil-heated
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758:Unit Operations of Chemical Engineering
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90:connected to the bottom of the column.
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361:as shown in image 5, or the column is
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789:
652:A typical application for distilling
525:
271:A continuous distillation is often a
1020:(2nd ed.). Marcel Dekker, Inc.
1006:
960:
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861:Perry's Chemical Engineers' Handbook
844:
552:Continuous distillation of crude oil
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216:component) begins to descend again.
1016:Gary, J.H.; Handwerk, G.E. (1984).
13:
587:-containing hydrocarbons such as
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14:
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534:Process intensifying alternatives
1199:
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1106:Distillation simulation software
1034:
979:
1083:by the Distillation Group, USA
1043:Petroleum Refinery Engineering
961:Kiss, Anton Alexandru (2013).
918:
819:
748:
723:
314:
1:
1045:(4th ed.). McGraw Hill.
902:Separation Process Principles
887:Chemical Engineering Progress
864:(6th ed.). McGraw-Hill.
830:(2nd ed.). McGraw Hill.
805:(1st ed.). McGraw-Hill.
761:(7th ed.). McGraw Hill.
716:
672:methods such as circulation,
668:to the concentrate. In other
454:theoretical equilibrium stage
232:, or even a gas or oil-fired
496:Overhead system arrangements
362:
184:
7:
679:
546:
517:Multicomponent distillation
376:
169:are the origin of the term
110:Distillation is one of the
10:
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1262:Spinning band distillation
1087:Distillation Lecture Notes
581:organic nitrogen compounds
439:
188:
153:. In such refineries, the
1275:
1239:
1208:
1197:
1148:
927:(Website of Raschig Gmbh)
799:Kister, Henry Z. (1992).
664:which allows for minimal
504:drum must include a vent
414:for enlarged tray image.)
382:
1191:Vapor–liquid equilibrium
577:organic sulfur compounds
425:vapor–liquid equilibrium
371:, and the purity of the
1221:Continuous distillation
711:Short path distillation
696:Fractional distillation
691:Extractive distillation
686:Azeotropic distillation
396:significant downtime).
273:fractional distillation
171:fractional distillation
39:Continuous distillation
1100:Petroleum Distillation
600:crude oil fractionator
469:structured sheet metal
416:
353:
200:
120:natural gas processing
106:Industrial application
35:
24:
1041:Nelson, W.L. (1958).
654:cannabis concentrates
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309:operating temperature
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30:
22:
1226:Fractionating column
1209:Industrial processes
1176:McCabe–Thiele method
828:Separation Processes
701:Fractionating column
540:Dividing Wall Column
344:Improving separation
293:McCabe–Thiele method
287:Design and operation
266:McCabe–Thiele method
151:petroleum refineries
97:). When distilling
84:fractionating column
16:Form of distillation
1068:Distillation Theory
904:. New York: Wiley.
826:King, C.J. (1980).
802:Distillation Design
277:vacuum distillation
161:, which are called
1240:Laboratory methods
1216:Batch distillation
1092:2022-08-12 at the
1079:2014-07-13 at the
706:Steam distillation
616:catalytic reformer
526:Distillation train
485:theoretical stages
481:structured packing
421:equilibrium stages
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338:flash vaporization
281:steam distillation
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95:chemical compounds
80:batch distillation
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1257:Rotary evaporator
1181:Theoretical plate
1000:10.1002/aic.14468
608:hydrodesulfurizer
430:theoretical plate
412:theoretical plate
334:sub-cooled liquid
322:superheated vapor
132:liquor production
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1349:Distillation
1328:Vacuum-based
1220:
1161:Dalton's law
1156:Raoult's law
1142:Distillation
1074:Distillation
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59:condensation
43:distillation
41:, a form of
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1323:Steam-based
1318:Salt-effect
1293:Destructive
575:as well as
563:compounds:
561:hydrocarbon
373:top product
315:Column feed
248:ratio, and
147:cannabinoid
140:hydrocarbon
55:evaporation
1308:Fractional
1303:Extractive
1283:Azeotropic
1276:Techniques
1149:Principles
741:0471488100
717:References
641:diesel oil
610:to remove
569:naphthenes
301:simulation
47:separation
1288:Catalytic
1252:Kugelrohr
777:cite book
624:molecules
583:and some
573:aromatics
565:paraffins
557:Petroleum
222:condenser
206:condensed
185:Principle
167:fractions
165:. These
163:fractions
155:crude oil
99:crude oil
1343:Category
1313:Reactive
1090:Archived
1077:Archived
1051:57010913
680:See also
636:kerosene
547:Examples
368:reboiler
214:volatile
143:solvents
128:coal tar
88:reboiler
73:residuum
64:volatile
1247:Alembic
630:value.
604:naphtha
593:olefins
589:phenols
440:Packing
295:or the
254:quality
234:furnace
69:bottoms
51:boiling
1166:Reflux
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620:reform
614:and a
612:sulfur
585:oxygen
502:reflux
389:reflux
383:Reflux
377:reflux
363:packed
246:reflux
224:. The
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1267:Still
410:(See
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1047:LCCN
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