production of ethanol by gavin chen

CHE 199 BIOFUELS FINAL PROJECT Gavin Chen

Production of Ethanol of 15

Production of Ethanol with Corn

Using Dry Milling Method

Section Page Number

Block Flow Diagram pg 2

Process Flow Diagram pg 3

Biological Pathway & Chemical Reactions pg 5

Mass and Energy Balance pg 6

Sizing a CSTR Fermenter pg 8

Piping and Instrumentation Diagram pg 9

Characterization of Streams pg 10

Hazard and Operability Study pg 11

Capital Expenditure pg 12

Operation Expenditure pg 13

Reference pg 15

Dec. 20th 2016

By Gavin Chen



Block Flow Diagram

The Dry Mill Process will happen in 4 basic steps

The first process is the preprocessing process. In this step, the dry corn feedstock would be

mashed into smaller particle sizes. Then the dry corn feedstock would be treated with fresh water

for hydrolysis process.

The second process is the liquefaction and the saccharification process. The hydrolyzed corn

feedstock would be treated with hot steam through jet cooker. In the liquefaction step, the

enzyme, Alpha Amylase, is added to perform saccharification for converting corn into glucose

slurry.

The third process is the fermentation process. The purpose of fermentation is to convert glucose

slurry to alcohol slurry. Gluco Amylase and yeast are required for this process. The residence

time of the glucose slurry should be between 50 to 60 hours, and it is determined to be 60 hours

for maximum conversion.

The forth process is the purification process. The alcohol slurry would be transferred to a

distillation column. The desired ethanol would be vaporized to the overhead of the column.

Then, the ethanol-water azeotrope would be further purify. The co-product, DDGS, would be

dried and put to a storage.



Process Flow Diagram

This process begins by breaking the dry corn feedstock from the storage tank (TK-110) into

smaller particle sizes through the Hammer Mill (V-410). Then the dry corn would be mixed with

fresh water(TK-120) to perform hydrolysis in the cyclone (TK-130).

The second step involves liquefaction and saccharification. The corn slurry from cyclone (TK-

130) would be transferred and heated through a steam jet cooker (E-210). This process

approximately takes about 30 to 40 minutes and the slurry is heated to 70 degrees C. Then, the

corn slurry is transferred to the liquefaction reactor (R-510) in order to convert corn slurry to

glucose slurry. The required enzyme, Alpha Amylase, would be added from the tank (TK-140).

The liquefaction process performs at the temperature between 85 to 95 degrees C. After the

liquefaction process, the glucose slurry would be discharged into a knock-out drum (E-220) for

the mash cooling process. When the temperature of the glucose slurry drops to 32 degrees C, the

glucose slurry would be ready for the fermentation process.

In the fermentation process (R-520), the entire process takes 60 hours for converting glucose

slurry to alcohol slurry with the maximum yield.

After the fermentation process, the next stage is the purification process. The alcohol slurry

would be transferred to the distillation column (T-310). The desired ethanol-water azeotrope

would be separated out in the overhead of the column through vaporization. The desired pure

ethanol product would be stored in the tank (TK-160). The remaining slurry would be discharged

from the bottom of the column. The ethanol-water azeotrope would be purified again through



molecular sieves (T-320&T-330) for extracting out the majority of the water component. The

remaining slurry would be transferred to the knock-out drum (V-430) through the centrifuge (V-

420). After the slurry gets dried, the DDGS would be stored in the cyclone (TK-170).



Biological Pathway

This report discusses the Dry Milling Method to produce Ethanol.

The process begins by adding process water to the milled corn grains, adjusting the pH to about

6, and adding a thermostable Alpha Amylase. The following step is starch liquefaction. After the

dry corn feedstock gets converted into glucose slurry by using thermal and pressure energy, the

glucose slurry gets transferred into the reactor for fermentation. While fermenting, the yeast,

Saccharomyces Cerevisiae, is added for ethanol production. The main reaction in the

fermentation stage is given as

𝐶6𝐻12𝑂6 + 2𝑃𝑖 + 2𝐴𝐷𝑃 → 2𝐶2𝐻5𝑂𝐻 + 2𝐶𝑂2 + 2𝐴𝑇𝑃 + 2𝐻2𝑂

𝐺𝑙𝑢𝑐𝑜𝑠𝑒 → 2 𝑒𝑡ℎ𝑎𝑛𝑜𝑙 + 2 𝑐𝑎𝑟𝑏𝑜𝑛 𝑑𝑖𝑜𝑥𝑖𝑑𝑒 + 𝑒𝑛𝑒𝑟𝑔𝑦

The theoretical yield is 0.511 𝑔 ethanol produced per gram glucose consumed. According to our

references and the adjustments due to the current market, the conversion factor of kg ethanol

produced per kg dry corn consumed is 0.3104. Our basis of corn feedstock is 1,000,000 metric

tons of corn feedstock which contains 85% dry corn and 15% moisture.

The following report discusses the process design of ethanol production starting with 1,000,000

metric tons of feedstock per hour as the initial mass flow rate to begin with.



Mass and Energy Balance

The theoretical yield of ethanol from starch:

(𝐶6𝐻10𝑂5)𝑛 + 𝐻2𝑂 → 𝐶6𝐻12𝑂6 → 2𝐶2𝐻5𝑂𝐻 + 2𝐶𝑂2

Assumptions:

𝑆𝑡𝑎𝑟𝑐ℎ(𝑘𝑔) = 0.6 𝐷𝑟𝑦𝐶𝑜𝑟𝑛(𝑘𝑔)

90% ethanol yield

𝑌𝑒𝑎𝑠𝑡 = 0.0008(𝐺𝑙𝑢𝑐𝑜𝑠𝑒 𝑆𝑙𝑢𝑟𝑟𝑦)

𝐴𝑙𝑝ℎ𝑎 𝐴𝑚𝑦𝑙𝑎𝑠𝑒 = 0.0001(𝐷𝑟𝑦 𝑐𝑜𝑟𝑛)

𝑚𝑦𝑒𝑎𝑠𝑡 = 172 𝑔/𝑚𝑜𝑙

Basis:

1,000,000𝑚𝑒𝑡𝑟𝑖𝑐 𝑡𝑜𝑛

𝑦𝑒𝑎𝑟𝐶𝑜𝑟𝑛 𝑓𝑒𝑒𝑑𝑠𝑡𝑜𝑐𝑘 𝑤𝑖𝑡ℎ 15% 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒

1,000,000𝑚𝑒𝑡𝑟𝑖𝑐 𝑡𝑜𝑛

𝑦𝑒𝑎𝑟 1.10231 𝑡𝑜𝑛

𝑚𝑒𝑡𝑟𝑖𝑐 𝑡𝑜𝑛 2000 𝑙𝑏

𝑡𝑜𝑛

𝑦𝑒𝑎𝑟

330 𝑑𝑎𝑦

𝑑𝑎𝑦

24 ℎ𝑟= 280,000

𝑙𝑏

ℎ𝑟 𝐶𝑜𝑟𝑛 𝐹𝑒𝑒𝑑𝑠𝑡𝑜𝑐𝑘

280,000𝑙𝑏

ℎ𝑟𝑐𝑜𝑟𝑛 ∗ (0.85) = 240,000

𝑙𝑏

ℎ𝑟 𝑑𝑟𝑦 𝑐𝑜𝑟𝑛

240,000𝑙𝑏

ℎ𝑟 𝑑𝑟𝑦 𝑐𝑜𝑟𝑛 (0.617) = 150,000

𝑙𝑏

ℎ𝑟 𝑆𝑡𝑎𝑟𝑐ℎ = 68,000

𝑘𝑔

ℎ 𝑆𝑡𝑎𝑟𝑐ℎ

= 380𝑘𝑚𝑜𝑙

ℎ 𝑆𝑡𝑎𝑟𝑐ℎ

Based on the stoichiometry:

380𝑘𝑚𝑜𝑙

ℎ𝑠𝑡𝑎𝑟𝑐ℎ + 380

𝑘𝑚𝑜𝑙

ℎ𝑊𝑎𝑡𝑒𝑟 → 380 𝑀𝑀

𝑘𝑚𝑜𝑙

ℎ 𝑔𝑙𝑢𝑐𝑜𝑠𝑒

→ 2(380𝑘𝑚𝑜𝑙

ℎ𝑒𝑡ℎ𝑎𝑛𝑜𝑙) + 2(380

𝑘𝑚𝑜𝑙

ℎ𝐶𝑂2)



Amount of water used in fermentation:

380𝑘𝑚𝑜𝑙

ℎ𝑤𝑎𝑡𝑒𝑟 = 6,900

𝑘𝑔

ℎ𝑤𝑎𝑡𝑒𝑟 = 15,000

𝑙𝑏

ℎ𝑤𝑎𝑡𝑒𝑟 = 30 𝑔𝑝𝑚 𝑤𝑎𝑡𝑒𝑟

Theoretical yield of glucose:

380 𝑘𝑚𝑜𝑙𝑔𝑙𝑢𝑐𝑜𝑠𝑒

ℎ𝑟 = 69,000

𝑘𝑔

ℎ𝑟𝑔𝑙𝑢𝑐𝑜𝑠𝑒 = 150,000

𝑙𝑏

ℎ𝑟 𝑔𝑙𝑢𝑐𝑜𝑠𝑒

Theoretical yield of ethanol and CO2:

2 (380𝑘𝑚𝑜𝑙

ℎ𝑒𝑡ℎ𝑎𝑛𝑜𝑙) = 760

𝑘𝑚𝑜𝑙

ℎ𝑟𝑒𝑡ℎ𝑎𝑛𝑜𝑙 = 35,000

𝑘𝑔

ℎ𝑒𝑡ℎ𝑎𝑛𝑜𝑙 = 77,000

𝑙𝑏

ℎ𝑟𝑒𝑡ℎ𝑎𝑛𝑜𝑙

= 195 𝑔𝑝𝑚 𝑒𝑡ℎ𝑎𝑛𝑜𝑙

2 (380𝑘𝑚𝑜𝑙

ℎ𝑟𝐶𝑂2) = 760

𝑘𝑚𝑜𝑙

ℎ𝑟𝐶𝑂2 = 34,000

𝑘𝑔

ℎ𝑟𝐶𝑂2 = 74,000

𝑙𝑏

ℎ𝑟𝐶𝑂2

Alpha Amylase Calculation:

0.0001 (280,000𝑙𝑏

ℎ𝑟𝐷𝑟𝑦 𝐶𝑜𝑟𝑛) = 28

𝑙𝑏

ℎ𝑟𝐴𝑙𝑝ℎ𝑎 𝐴𝑚𝑦𝑙𝑎𝑠𝑒

Yeast Calculation:

0.0008 (28 𝑙𝑏

ℎ𝑟𝐴𝑙𝑝ℎ𝑎 𝑎𝑚𝑦𝑙𝑎𝑠𝑒 + 150,000

𝑙𝑏

ℎ𝑟𝑔𝑙𝑢𝑐𝑜𝑠𝑒 + 15,000

𝑙𝑏

ℎ𝑟𝑤𝑎𝑡𝑒𝑟) = 140

𝑙𝑏

ℎ𝑟𝑦𝑒𝑎𝑠𝑡

Theoretical Yield of Ethanol:

0.90 (77,000𝑙𝑏

ℎ𝑟) = 69,000

𝑙𝑏

ℎ𝑟𝑒𝑡ℎ𝑎𝑛𝑜𝑙 = 180 𝑔𝑝𝑚 𝑒𝑡ℎ𝑎𝑛𝑜𝑙

Amount of water outlet:

15,000𝑙𝑏

ℎ𝑟𝑤𝑎𝑡𝑒𝑟 − (0.90 ∗ 15,000

𝑙𝑏

ℎ𝑟𝑤𝑎𝑡𝑒𝑟) = 1,500

𝑙𝑏

ℎ𝑟𝑤𝑎𝑡𝑒𝑟 = 3 𝑔𝑝𝑚 𝑤𝑎𝑡𝑒𝑟

Amount of glucose outlet:

150,000𝑙𝑏

ℎ𝑟𝑔𝑙𝑢𝑐𝑜𝑠𝑒 − (0.90 ∗ 150,000

𝑙𝑏

ℎ𝑟𝑔𝑙𝑢𝑐𝑜𝑠𝑒) = 15,000

𝑙𝑏

ℎ𝑟 𝑔𝑙𝑢𝑐𝑜𝑠𝑒

Total amount of beer slurry:

69,000𝑙𝑏 𝑒𝑡ℎ𝑎𝑛𝑜𝑙

ℎ𝑟+ 15,000

𝑙𝑏 𝑤𝑎𝑡𝑒𝑟

ℎ𝑟+ 150,000

𝑙𝑏 𝑔𝑙𝑢𝑐𝑜𝑠𝑒

ℎ𝑟+ 28

𝑙𝑏 𝑎𝑙𝑝ℎ𝑎 𝑎𝑚𝑦𝑙𝑎𝑠𝑒

ℎ𝑟

+ 140𝑙𝑏 𝑦𝑒𝑎𝑠𝑡

ℎ𝑟≈ 230,000

𝑙𝑏

ℎ𝑟𝑏𝑒𝑒𝑟 𝑠𝑙𝑢𝑟𝑟𝑦



Sizing a CSTR Fermenter

Calculations of Alcohol Slurry out of Fermenter

150,000 𝑙𝑏 𝑔𝑙𝑢𝑐𝑜𝑠𝑒

ℎ𝑟

𝑘𝑔

2.205= 68,000

𝑘𝑔 𝑔𝑙𝑢𝑐𝑜𝑠𝑒

ℎ𝑟

𝑚3

1540 𝑘𝑔 𝑔𝑙𝑢𝑐𝑜𝑠𝑒= 44

𝑚3

ℎ𝑟𝑔𝑙𝑢𝑐𝑜𝑠𝑒

1,500 𝑙𝑏 𝑤𝑎𝑡𝑒𝑟

ℎ𝑟

𝑘𝑔

2.205= 680

𝑘𝑔 𝑤𝑎𝑡𝑒𝑟

ℎ𝑟

𝑚3

1000 𝑘𝑔 𝑔𝑙𝑢𝑐𝑜𝑠𝑒= 0.68

𝑚3

ℎ𝑟 𝑤𝑎𝑡𝑒𝑟

69,000 𝑙𝑏 𝑒𝑡ℎ𝑎𝑛𝑜𝑙

ℎ𝑟

𝑘𝑔

2.205= 32,000

𝑘𝑔 𝑒𝑡ℎ𝑎𝑛𝑜𝑙

ℎ𝑟

𝑚3

789 𝑘𝑔 𝑒𝑡ℎ𝑎𝑛𝑜𝑙= 40

𝑚3

ℎ𝑟 𝑒𝑡ℎ𝑎𝑛𝑜𝑙

Total Mass of Beer

68,000𝑘𝑔 𝑔𝑙𝑢𝑐𝑜𝑠𝑒

ℎ𝑟 + 680

𝑘𝑔 𝑤𝑎𝑡𝑒𝑟

ℎ𝑟 + 32,000

𝑘𝑔 𝑒𝑡ℎ𝑎𝑛𝑜𝑙

ℎ𝑟= 100,000

𝑘𝑔 𝑏𝑒𝑒𝑟 𝑠𝑙𝑢𝑟𝑟𝑦

ℎ𝑟

Total Volumetric Flow Rate

4 𝑚3

ℎ𝑟𝑔𝑙𝑢𝑐𝑜𝑠𝑒 + 0.68

𝑚3

ℎ𝑟 𝑤𝑎𝑡𝑒𝑟 + 40

𝑚3

ℎ𝑟 𝑔𝑙𝑢𝑐𝑜𝑠𝑒 = 45

𝑚3

ℎ𝑟𝑏𝑒𝑒𝑟 𝑠𝑙𝑢𝑟𝑟𝑦

Density of Beer Slurry

100,000𝑘𝑔 𝑏𝑒𝑒𝑟 𝑠𝑙𝑢𝑟𝑟𝑦

ℎ𝑟

ℎ𝑟

45 𝑚3= 2254

𝑘𝑔

𝑚3 𝑏𝑒𝑒𝑟 𝑠𝑙𝑢𝑟𝑟𝑦

GPM Flow Rate of Beer Slurry

100,000 𝑘𝑔 𝑏𝑒𝑒𝑟 𝑠𝑙𝑢𝑟𝑟𝑦

ℎ𝑟

𝑚3

2254 𝑘𝑔 𝑏𝑒𝑒𝑟 𝑠𝑙𝑢𝑟𝑟𝑦 264

𝑔𝑎𝑙

𝑚𝑖𝑛

ℎ𝑟

60 𝑚𝑖𝑛 = 197 gpm beer slurry

Total Capacity needed for 60 hours Residence Time

197 𝑔𝑎𝑙𝑙𝑜𝑛 𝑏𝑒𝑒𝑟𝑦 𝑠𝑙𝑢𝑟𝑟𝑦

𝑚𝑖𝑛 60

𝑚𝑖𝑛

ℎ𝑟 60 ℎ𝑟 𝑟𝑒𝑠𝑖𝑑𝑒𝑛𝑐𝑒 𝑡𝑖𝑚𝑒 = 707,843 gallons of beer

slurry_out

707,843 gallons # 𝑜𝑓 𝐶𝑆𝑇𝑅 𝐹𝑒𝑟𝑚𝑒𝑛𝑡𝑒𝑟𝑠

15,000 𝑔𝑎𝑙𝑙𝑜𝑛𝑠 ~ 47 𝐶𝑆𝑇𝑅 𝐹𝑒𝑟𝑚𝑒𝑛𝑡𝑒𝑟𝑠



Piping and Instrumentation Diagram

This is the P&ID of R-520 Fermenter. Overall, there are 4 loops for monitoring this fermenter.

In Loop 1, we are detecting the flow rate of glucose slurry going in.

In Loop 2, we are detecting the temperature of steam stream going into the jacket in order to

control the flow of steam and to adjust the flow of condensate.

In Loop 3, we are detecting the pressure of the CO2 gas product coming out from the fermenter.

In Loop 4, we are detecting the leveling control in order to adjust the flow of the product stream

going out from the fermenter.

For the inlet and the outlet streams, 7” Schedule 40 Stainless Steel pipes are used for transferring

the glucose slurry and the alcohol slurry.

For the gas product stream, 4” Schedule 40 Stainless Steel pipe is used.

For the steam streams, 4” Schedule 40 Stainless Steel pipes are used for the incoming steam and

and the outgoing condensate.



Characterization of Streams

These testing methods have been taken from ASTM method. ASTM standards are used world

wide to improve product quality, enhance safety.

D887 (11.02) is a practice used for sampling water-formed deposits.

E1758 (11.06) is test method for determination of carbohydrates in biomass by HPLC.

D3048 (15.04) is test method for enzymes assay

E346 (15.05) is test method for analysis of ethanol



Hazard and Operability Study

If reactor temperature is too high, set parameters. Fouled or failed exchanger tubes. Fire

situation. Defective control valve. Internal Fires. Heating fluid/medium leaking. Faulty

instrumentation and control.

If higher pressure inside reactor happens, Surge problems for pump stop/starting or valve turning

on/off. Relief valve isolated. Thermal overpressure. Boiling. Worst case, explosion.

If reaching high level in reactor, reactor outlet blocked or isolated. Inflow greater than outflow.

Faulty level measurement. Pressure surges for sudden change in the velocity of the fluids; caused

by pump starting/stopping or valve opening/closing.

If power outage happens, lightning, high winds, ice storms. Accidents at power plants and

transmission lines.



Capital Expenditure



Operation Expenditure

In the Operation Expenditure, we are estimating the overall costs of the entire operation of our

Dry Milling Ethanol plant.

The basis of the feedstock is 280,000 𝑙𝑏 𝐷𝑟𝑦 𝐶𝑜𝑟𝑛

ℎ𝑟. As the kg-ethanol-to-kg-corn conversion factor

given in the textbook, Biofuels Engineering Process Technology by C. Drapcho, N. Nhuan, and

T. Walker, being applied, the annual production of ethanol is estimated to be 90,000,000 𝑔𝑎𝑙𝑙𝑜𝑛𝑠 𝐸𝑡ℎ𝑎𝑛𝑜𝑙

𝑦𝑒𝑎𝑟 . According to the price of ethanol from Nasdaq.com, one gallon of ethanol is sold

for $1.80 USD. As result, the estimated annual revenue comes out to be around $162 million

USD.

The operating cost of steam is the major component in our budget. It takes 8 million dollars for

having 330,000 lb/hr steam in supporting each of the 47 fermenters we have and 1 reactor for

liquification over a year. The price of steam varies from $2 𝑈𝑆𝐷

1000 𝑙𝑏 𝑆𝑡𝑒𝑎𝑚 to

$3 𝑈𝑆𝐷

1000 𝑙𝑏 𝑆𝑡𝑒𝑎𝑚 .

Unit cost of enzymes is respectively high comparing to others. The costs of enzymes include the

cost of Alpha Amylase in liquefaction, and the cost Glu Amylase in fermentation.

The cost of maintenance is 5% of the CapEx.

For the labor distribution, we plan to have 42 operators alternating 3 shifts a day. 14 engineers

doing safety check, 14 engineers doing maintenance, and 7 operating manager.

Due to the annual revenue, $162 millions USD, the operating cost, $155 millions USD, and the

capital cost, $17 millions, can be balanced off as a result of having positive $8 million USD.

The profit in 1st is estimated to be $7 millions USD.



Operation Expenditure-Calculation

BASIS 240,000𝑙𝑏 𝐷𝑟𝑦 𝐶𝑜𝑟𝑛

ℎ𝑟

Annual Ethanol Production

240,000𝑙𝑏 𝐷𝑟𝑦 𝐶𝑜𝑟𝑛

ℎ𝑟

𝑘𝑔

2.205 𝑙𝑏 0.3104 𝑘𝑔 𝐸𝑡ℎ𝑎𝑛𝑜𝑙

𝑘𝑔 𝐷𝑟𝑦 𝐶𝑜𝑟𝑛

𝑚3

789𝑘𝑔 264.1 𝑔𝑎𝑙

𝑚3 24 ℎ𝑟

𝑑𝑎𝑦 330 𝑑𝑎𝑦

𝑦𝑒𝑎𝑟

= 90,000,000 𝑔𝑎𝑙𝑙𝑜𝑛 𝐸𝑡ℎ𝑎𝑛𝑜𝑙

𝑦𝑒𝑎𝑟

Revenue from Ethanol

90,000,000 𝑔𝑎𝑙 𝐸𝑡ℎ𝑎𝑛𝑜𝑙

𝑦𝑒𝑎𝑟

$ 1.80 𝑈𝑆𝐷

𝑔𝑎𝑙𝑙𝑜𝑛 𝐸𝑡ℎ𝑎𝑛𝑜𝑙= $162,000,000 𝑈𝑆𝐷

Annual Amount of Steam

90,000,000 𝑔𝑎𝑙 𝐸𝑡ℎ𝑎𝑛𝑜𝑙

𝑦𝑒𝑎𝑟 48,000 𝐵𝑡𝑢 𝑆𝑡𝑒𝑎𝑚

𝑔𝑎𝑙 𝐸𝑡ℎ𝑎𝑛𝑜𝑙

𝐵𝐻𝑃

33479 𝐵𝑡𝑢 34.5 𝑙𝑏

𝐵𝐻𝑃 = 4,500,000,000

𝑙𝑏 𝑆𝑡𝑒𝑎𝑚

𝑦𝑒𝑎𝑟

Annual Cost of Steam

4,500,000,000 𝑙𝑏 𝑆𝑡𝑒𝑎𝑚

𝑦𝑒𝑎𝑟

$3𝑈𝑆𝐷

1000 𝑙𝑏 𝑆𝑡𝑒𝑎𝑚= $14,000,000 𝑈𝑆𝐷

Annual Amount of Corn Feedstock

280,000 𝑙𝑏 𝑐𝑜𝑟𝑛 𝑓𝑒𝑒𝑑𝑠𝑡𝑜𝑐𝑘

ℎ𝑟

24

𝑑𝑎𝑦 330 𝑑𝑎𝑦

𝑦𝑒𝑎𝑟= 2,200,000,000

𝑙𝑏 𝑐𝑜𝑟𝑛 𝑓𝑒𝑒𝑑𝑠𝑡𝑜𝑐𝑘

𝑦𝑒𝑎𝑟

Annual Cost of Corn Feedstock

2,200,000,000 𝑙𝑏 𝑐𝑜𝑟𝑛 𝑓𝑒𝑒𝑑𝑠𝑡𝑜𝑐𝑘

𝑦𝑒𝑎𝑟

$0.057 𝑈𝑆𝐷

𝑙𝑏 𝑐𝑜𝑟𝑛 𝑓𝑒𝑒𝑑𝑠𝑡𝑜𝑐𝑘= $126,000,000 𝑈𝑆𝐷



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