WO2010105049A2 - Improved process for guniting refractory mixes using conventional dry gunning equipment and refractory mixes for use in same - Google Patents
Improved process for guniting refractory mixes using conventional dry gunning equipment and refractory mixes for use in same Download PDFInfo
- Publication number
- WO2010105049A2 WO2010105049A2 PCT/US2010/026972 US2010026972W WO2010105049A2 WO 2010105049 A2 WO2010105049 A2 WO 2010105049A2 US 2010026972 W US2010026972 W US 2010026972W WO 2010105049 A2 WO2010105049 A2 WO 2010105049A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- dry
- liquid binder
- binder
- nozzle
- refractory material
- Prior art date
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
- B05B7/14—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas designed for spraying particulate materials
- B05B7/1404—Arrangements for supplying particulate material
- B05B7/1431—Arrangements for supplying particulate material comprising means for supplying an additional liquid
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
- B28C5/02—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions without using driven mechanical means effecting the mixing
- B28C5/026—Mixing guns or nozzles; Injector mixers
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
- C04B35/6303—Inorganic additives
- C04B35/6306—Binders based on phosphoric acids or phosphates
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
- C04B35/6303—Inorganic additives
- C04B35/6316—Binders based on silicon compounds
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
- C04B35/632—Organic additives
- C04B35/634—Polymers
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/66—Monolithic refractories or refractory mortars, including those whether or not containing clay
Definitions
- the invention relates to a process for guniting refractory mixes using dry gunning equipment using a modified binder system, as well as to the refractory mixes for use in such a process.
- Refractory materials are designed to retain their strength at high temperatures and are thus used, for among other things, as liners in furnaces, incinerators and ovens.
- the refractory materials may be applied in a number of known ways including by casting, pumping, shotcreting or dry gunning.
- casting is suitable for creating liners in many applications, it requires significant time and expense in creating and using forms for the casting. Furthermore, it is not always feasible to build forms depending on the shape of the casting and or its application.
- Pumping a wet castable through a hose also has problems. Among other things, pumping a wet material through equipment can often to lead to plugged lines. For example, variations in the raw materials and/or conditions at the job site can lead to a marginally pumpable material that can cause plugging and setting of the material in the hoses, thus shutting down the job. Additionally, pumping requires the use of expensive equipment.
- shotcreting which involves pneumatically projecting mortar or concrete onto a surface at a high velocity, may work, it requires the use of expensive equipment and a large work crew to operate. Shotcreting introduces a setting agent at the nozzle, where it is not evenly distributed throughout the refractory mass, thereby leading to variations in material properties. In order for shotcreting to be used with colloidal silica bonded materials, it is generally necessary to use 9-10% colloidal silica, thereby resulting in 6% to 6.6% water in the finished product. To prevent the castable from slumping on the wall, a water-containing setting agent is injected at the nozzle to cause the mass to harden upon being applied to the surface.
- the increased level of water required in the pumping and shotcreting methods in order to achieve a fluid consistency results in a higher porosity product. This results in decreased properties and resistance to slag and metal penetration. Additionally, the high percentage of water also increases the drying time for these methods.
- the present invention is an improvement over the prior art dry gunniting systems and methods, in one embodiment, in that the design of the dry mix and the application method allow the installation of refractory with properties that surpass regular gunnite mixes and shotcrete products.
- One aspect of the invention utilizes gunning mixes that do not contain cement.
- the dry refractory mix also may include a setting agent that is homogeneously blended with the other materials.
- dry refractory material material is fed into a hopper of a gunnite machine and is then introduced into an air flow and conveyed by air through one or more hoses to a nozzle.
- a liquid binder is introduced into the air flow for mixing with the suspended dry refractory material at or before the nozzle.
- a fitting such as a water ring with holes, may be used for injecting the binder into the air flow containing the dry refractory material.
- a pump or other know pressurizing means is used to pressurize the binder and force it flow to the fitting.
- a needle valve may be used to control the amount of liquid binder introduced into the system.
- the dry refractory material is discharged through the nozzle for application to the surface with the liquid binder. It is therefore an object of the present invention to provide a new and improved process for applying refractory mixes.
- Another object of the present invention is to provide a new and improved process for applying refractory mixes that limits the amount of water needed.
- Yet another object of the present invention is to eliminate the need to use a cement in a dry gunning application.
- Still another object of the invention is to provide refractory mixes having increased physical properties.
- FIG. 1 is a front perspective view of one embodiment of a dry gunning machine.
- FIG. 2 is a top perspective view of a half section or half height bowl and spacer.
- FIG. 3 is a partial perspective view of a dry gunning machine of Fig. 1 showing a half height bowl.
- FIG. 4 is a front perspective view of one embodiment of a nozzle showing a nozzle extension.
- FIG. 5 is a front elevation view of the nozzle and nozzle extension of Fig. 4.
- FIGS. 6 and 7 are perspective views illustrating the application of material to a surface through a nozzle.
- FIG. 8 is a front perspective view of a water ring.
- One aspect of the present invention is directed to a line of no-cement gunning mixes that can be applied using conventional guniting equipment such as Allentown and Blastcrete pneumatic guns.
- the dry mix which is provided into a storage area for the guniting equipment, is conveyed by air though hoses and the binder is added at the nozzle or application end of the hose.
- the design of these mixes and the application method allow the installation of refractory with properties that surpass regular gunite mixes and shotcrete products.
- the binder and the mix design result in installed product with excellent thermal shock resistance, high hot load strength, lower porosity and excellent resistance to chemical attack.
- no-cement gunning mixes include, but are not limited to, materials comprising 0-95 percent aluminum oxide, 0-95 percent alumino- silicate compounds, 0-100 percent zircon, 0-95 percent Alumina-Zirconia-Silicate(AZS), 0-100 percent Silica, 0-90 percent silicon carbide, or 0-80 percent chrome oxide with the remaining balance being alumina.
- the formulations designed for use in this invention are similar to those normally used for application with a Shotcrete or gunnite installation.
- the preferred modification is that the amount of fine powders in the formulation are reduced by approximately 5% since the binder is added to the material in the nozzle.
- the dry refractory mix includes a setting agent that is homogeneously blended with the other materials.
- FIG. 1 one embodiment of a known gunite machine 10 to apply the refractory mixes is shown. While a number of gunite machines may be utilized, it is appreciated that good results will occur through use of a pneumatic gunite machine such as an Allentown or Blastcrete gun (as shown in Figure 1).
- the gunnite machine include a hopper 12 for receiving a refractory material, and a pump 14 for generating an air flow through hose 16.
- a valve 18 on the connector for the hose 16 can regulate the flow of materials and air through the hose 16.
- a coupling member 20 at the end of the connector permits a hose 30 to be attached or connected thereto in a known way.
- An air compressor capable of maintaining a minimum pressure of 80 psi at the gun and an air flow of at least 450 cfm is also recommended.
- Material can be feed into the hopper 12 in a variety of ways, including but not limited to, by individual small bags, bulk bags with flow control spouts or surge hoppers placed above the hopper.
- the feed rate and mechanism needs to be reduced from what is generally supplied by the gun manufacturer.
- the gun is set up for high production, high volume gunning of high cement gun mixes.
- the nature of the refractory gunnite mixes in this invention requires intimate mixing of the binder with the dry powder to achieve superior results.
- Blastcrete has what is referred to a "half sector bowl".
- the openings in the feed wheel are the same but the height of the bowl is one half of the high production bowl.
- the half sector bowl 40 defines a plurality of open spaces 42 that allows a more even flow of material into the air stream or air flow and somewhat reduces the amount of material in the hose 16. This allows smoother gunning and complete wetting of the material by the liquid at the nozzle.
- the liquid binder provided for the refractory mixes may be supplied in large tote tanks or if desired, in five gallon pails.
- the binder is preferably introduced into the dry material at or proximate the nozzle.
- a diaphragm pump can be use to pump the binder to the "water ring" 50 between the hose 30 and the nozzle 60.
- the "water ring” 50 is a circular tube arrangement with multiple fine holes 52 drilled into the inner surface. In the preferred embodiment, an 8 hole ring is used.
- the binder is delivered through the binder line 70 using a series of high pressure jets into the passing material at the ring 50.
- a needle valve 72 may be used to precisely control the amount of liquid binder introduced into the ring 50 through tubing or connector 74. Too much binder will result in slumping and too little will cause excessive dusting and rebound. It is appreciated that amount of pressure needed will vary depending on the needed flow rate and addition rate, as well as the type of ring or fitting used.
- the binder pump should supply the binder to the high pressure jets with a minimum of 100 psi to increase the wetting efficiency, reduces the amount of binder used, reduce dusting and rebound and maximize the physical properties of the material.
- the binder may be discharged under a minimum of 20 psi differential pressure to the material transport hose.
- the binder should be delivered at a pressure sufficient for injection into the air stream transporting the suspended dry refractory aggregates.
- liquid binders includes, but are not limited to, sodium silicate, potassium silicate, a resin (nouvalac, phenolic, aqueous and non aqueous polymers) or a binder that includes colloidal silica or other dispersed colloidal particles.
- the binder does not necessarily need to contain water, only that it is a liquid that can be pumped and injected into the air stream containing the dry refractory particles, or a binder that includes a colloidal silica or dispersed colloidal particles.
- a binder includes a colloidal silica solution composed of colloidal silica particles dispersed in water at a 10-50% concentration level. In another embodiment, a portion of the fine particles of the refractory is predispersed in the colloidal silica liquid.
- the process of the present invention injects about 4% to 30% colloidal silica into the dry refractory material. Where 9.0 to 11.0% colloidal silica is injected into the dry material, this equals an addition of 5.4-6.6% water from the binder solution. This amount of water addition represents a significant reduction of water in the finished materials from prior gunnite processes. Less water results in a lower porosity product, which provides improved properties and resistance to slag and metal penetration. It is appreciated that the amount of colloidal silica used can vary depending upon the particular dry material used.
- a nozzle extension 62 and double bubble nozzle 60 may be used to allow improved mixing of the liquid and the dry material before exiting the nozzle 60.
- this extension 62 can be 12 to 24 inches long.
- the needle valve control can be mounted next to the nozzle while the liquid is introduced back 12-24 inches from the nozzle.
- one option for use with the nozzle extension is to use two double bubble nozzles fitted together in series. The binder and dry material mix very well using this arrangement. Some installers find the double bubble nozzle arrangement easier to use as compared to an extension.
- nozzle extension or double bubble nozzle an 8 hole water ring and pressurized binder delivery system will provide adequate wetting of the refractory before it exits the nozzle.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Structural Engineering (AREA)
- Inorganic Chemistry (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Mechanical Engineering (AREA)
- Furnace Housings, Linings, Walls, And Ceilings (AREA)
- Nozzles (AREA)
- Ceramic Products (AREA)
Abstract
Description
Claims
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
MX2011009527A MX2011009527A (en) | 2009-03-11 | 2010-03-11 | Improved process for guniting refractory mixes using conventional dry gunning equipment and refractory mixes for use in same. |
EP10751411.9A EP2406015B1 (en) | 2009-03-11 | 2010-03-11 | Improved process for guniting refractory mixes using conventional dry gunning equipment |
US13/120,130 US8784943B2 (en) | 2009-03-11 | 2010-03-11 | Process for guniting refractory mixes using conventional dry gunning equipment and refractory mixes for use in same |
CA2755482A CA2755482C (en) | 2009-03-11 | 2010-03-11 | Improved process for guniting refractory mixes using conventional dry gunning equipment and refractory mixes for use in same |
BRPI1008960A BRPI1008960A2 (en) | 2009-03-11 | 2010-03-11 | improved process for refractory mixtures using conventional dry mix accelerating equipment and refractory mixtures for use therein |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15918309P | 2009-03-11 | 2009-03-11 | |
US60/159,183 | 2009-03-11 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2010105049A2 true WO2010105049A2 (en) | 2010-09-16 |
WO2010105049A3 WO2010105049A3 (en) | 2011-01-13 |
Family
ID=42729104
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2010/026972 WO2010105049A2 (en) | 2009-03-11 | 2010-03-11 | Improved process for guniting refractory mixes using conventional dry gunning equipment and refractory mixes for use in same |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP2406015B1 (en) |
BR (1) | BRPI1008960A2 (en) |
CA (1) | CA2755482C (en) |
MX (1) | MX2011009527A (en) |
WO (1) | WO2010105049A2 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN104549816A (en) * | 2014-11-28 | 2015-04-29 | 山东科技大学 | Low-rebound rate and low-dust concrete nozzle device in anchor spray shoring engineering |
DE102016124102A1 (en) | 2016-12-12 | 2018-06-14 | Refratechnik Holding Gmbh | Mixing nozzle for a shotcrete application device, as well as shotcrete application device with such a mixing nozzle and shotcrete application method |
DE102016124101A1 (en) | 2016-12-12 | 2018-06-14 | Refratechnik Holding Gmbh | Mixing nozzle for a shotcrete application device, as well as shotcrete application device with such a mixing nozzle and shotcrete application method |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4239397A (en) * | 1974-08-02 | 1980-12-16 | Gote Liljegren | Method for manufacturing shotcrete structures using a material having high impact resistance and optimum deformation properties |
EP0307066A2 (en) * | 1987-09-11 | 1989-03-15 | Elkem A/S | Method of shotcreting |
EP0506421A1 (en) * | 1991-03-27 | 1992-09-30 | Elkem A/S | Method for shotcreting |
US5961712A (en) * | 1996-05-24 | 1999-10-05 | Sungeric International, Inc. | Method for making shotcrete and such compositions |
US20040144859A1 (en) * | 2003-01-29 | 2004-07-29 | Specialty Minerals (Michigan) Inc. | Apparatus for the gunning of a refractory material and nozzles for same |
US20080314084A1 (en) * | 2007-06-19 | 2008-12-25 | Connors Sr Charles W | Refractory composition for glass melting furnaces |
Family Cites Families (10)
Publication number | Priority date | Publication date | Assignee | Title |
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US2533118A (en) * | 1947-08-12 | 1950-12-05 | Harry J Kahn | Sodium silicate cement composition |
JPS5817639Y2 (en) | 1976-02-02 | 1983-04-09 | 東京窯業株式会社 | Nozzle for spraying powder materials |
FR2407058A1 (en) | 1977-10-26 | 1979-05-25 | Roche Maurice | Continuous mixer for concrete projected by lance - has chamber for preparing cement binder which is delivered to region behind lance for addition of dry aggregate |
US4412863A (en) * | 1981-09-04 | 1983-11-01 | Ppg Industries, Inc. | Inorganic cement compositions having controlled thermal expansion coefficients |
JPS6086079A (en) | 1983-10-17 | 1985-05-15 | 品川白煉瓦株式会社 | Refractory composition for spray work |
US4673594A (en) | 1984-10-12 | 1987-06-16 | Manville Service Corporation | Method for applying a layer of fiber on a surface and a refractory material produced thereby |
JPH0341818Y2 (en) | 1984-11-30 | 1991-09-02 | ||
US6004626A (en) | 1998-07-10 | 1999-12-21 | North American Refractories Co. | High pressure/volume process for wet shotcreting a refractory castable |
DE10023170B4 (en) | 2000-05-11 | 2006-04-27 | Kurt Wolf VELCO Gesellschaft für Förder-, Spritz- und Silo-Anlagen mbH | Device for moistening dry spraying masses in the conveying line |
US20080156899A1 (en) | 2004-04-05 | 2008-07-03 | Shinagawa Refractories Australasia Pty Ltd | Slurry Installation Method and Apparatus |
-
2010
- 2010-03-11 EP EP10751411.9A patent/EP2406015B1/en not_active Revoked
- 2010-03-11 MX MX2011009527A patent/MX2011009527A/en active IP Right Grant
- 2010-03-11 CA CA2755482A patent/CA2755482C/en active Active
- 2010-03-11 BR BRPI1008960A patent/BRPI1008960A2/en active Search and Examination
- 2010-03-11 WO PCT/US2010/026972 patent/WO2010105049A2/en active Application Filing
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4239397A (en) * | 1974-08-02 | 1980-12-16 | Gote Liljegren | Method for manufacturing shotcrete structures using a material having high impact resistance and optimum deformation properties |
EP0307066A2 (en) * | 1987-09-11 | 1989-03-15 | Elkem A/S | Method of shotcreting |
EP0506421A1 (en) * | 1991-03-27 | 1992-09-30 | Elkem A/S | Method for shotcreting |
US5961712A (en) * | 1996-05-24 | 1999-10-05 | Sungeric International, Inc. | Method for making shotcrete and such compositions |
US20040144859A1 (en) * | 2003-01-29 | 2004-07-29 | Specialty Minerals (Michigan) Inc. | Apparatus for the gunning of a refractory material and nozzles for same |
US20080314084A1 (en) * | 2007-06-19 | 2008-12-25 | Connors Sr Charles W | Refractory composition for glass melting furnaces |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN104549816A (en) * | 2014-11-28 | 2015-04-29 | 山东科技大学 | Low-rebound rate and low-dust concrete nozzle device in anchor spray shoring engineering |
DE102016124102A1 (en) | 2016-12-12 | 2018-06-14 | Refratechnik Holding Gmbh | Mixing nozzle for a shotcrete application device, as well as shotcrete application device with such a mixing nozzle and shotcrete application method |
DE102016124101A1 (en) | 2016-12-12 | 2018-06-14 | Refratechnik Holding Gmbh | Mixing nozzle for a shotcrete application device, as well as shotcrete application device with such a mixing nozzle and shotcrete application method |
WO2018108679A1 (en) | 2016-12-12 | 2018-06-21 | Refratechnik Holding Gmbh | Mixing nozzle for a gunned-concrete application device, gunned-concrete application device having such a mixing nozzle, and gunned-concrete application method |
WO2018108678A1 (en) | 2016-12-12 | 2018-06-21 | Refratechnik Holding Gmbh | Mixing nozzle for a shotcrete application device, and a shotcrete application device comprising such a mixing nozzle, and a shotcrete application method |
Also Published As
Publication number | Publication date |
---|---|
MX2011009527A (en) | 2011-12-16 |
EP2406015B1 (en) | 2020-07-08 |
BRPI1008960A2 (en) | 2016-03-15 |
WO2010105049A3 (en) | 2011-01-13 |
CA2755482A1 (en) | 2010-09-16 |
CA2755482C (en) | 2014-05-27 |
EP2406015A4 (en) | 2018-01-10 |
EP2406015A2 (en) | 2012-01-18 |
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