United States
Environmental Protection
Agency
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EPA-450/3-89-18
May 1989
Air
Projected Impacts of
Alternative Participate
Matter New Source
Performance Standards
for Industrial-Commercial
Institutional Nonfossil
Fuel-Fired Steam
Generating Units
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EPA-450/3-89-18
PROJECTED IMPACTS OF
ALTERNATIVE PART1CULATE MATTER
NEW SOURCE PERFORMANCE STANDARDS FOR
INDUSTRIAL-COMMERCIAL-INSTITUTIONAL
NONFOSSIL FUEL-FIRED STEAM GENERATING UNITS
Emission Standards Division
U.S. Environmental Protection Agency
Office of Air and Radiation
Office of Air Quality Planning and Standards
Research Triangle Park, N.C. 27711
May 1989
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This report has been reviewed by the Emission Standards Division of the
Office of Air Quality Planning and Standards, EPA, and approved for
publication. Mention of trade names or commercial products is not intended
to constitute endorsement or recommendation of use. Copies of the report are
available through the Library Service Office (MD-35), U.S. Environmental
Protection Agency, Research Triangle Park, N.C. 27711, or from National
Technical Information Services, 5285 Port Royal Road, Springfield,
Virginia 22161.
11
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TABLE OF CONTENTS
SECTION PAGE
1.0 INTRODUCTION 1
2.0 SUMMARY 2
3.0 PROJECTIONS OF NEW WOOD-FIRED SMALL BOILERS 5
4.0 NATIONAL IMPACTS 8
4.1 ENVIRONMENTAL IMPACTS 8
4.2 COST IMPACTS 11
4.3 ENERGY IMPACTS 12
5.0 REFERENCES 13
iii
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LIST OF TABLES
TABLE
2-1
3-1
4-1
4-2
NATIONAL IMPACTS OF REGULATORY ALTERNATIVES FOR PM
CONTROLS ON SMALL WOOD-FIRED BOILERS IN 1993
PROJECTIONS OF NEW WOOD-FIRED SMALL BOILERS BASED
ON ABMA SALES DATA (1985 AND 1986)
ALTERNATIVE PM CONTROL LEVELS FOR NONFOSSIL FUEL- FIRED . .
BOILERS
NATIONAL IMPACTS OF REGULATORY ALTERNATIVES FOR PM
CONTROLS ON SMALL WOOD-FIRED BOILERS IN 1993
PAG
3
6
9
10
IV
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1.0 INTRODUCTION
This report presents projected environmental, cost, and energy impacts
of alternative new source performance standards (NSPS) for small nonfossil
fuel-fired steam generating units (i.e., boilers). Small boilers are defined
as industrial-commercial-institutional units having a heat input capacity of
29 MW (100 million Btu/hour) or less.
The two categories of nonfossil fuels burned in small boilers are wood
and solid waste. Solid waste that meets the definition of municipal solid
waste (MSW) will be addressed under a separate NSPS. Wood is the most
commonly used nonfossil fuel among small boilers, as discussed in the
memorandum "Population Projection for Small Mixed Fuel-Fired Steam Generating
Units." Since wood will be the only nonfossil fuel covered by standards
developed for this source category, the impacts of alternative standards are
evaluated for small wood-fired boilers. In addition, since wood contains
negligible amounts of sulfur, alternative sulfur dioxide (SO-) emission
standards will not be developed for wood combustion. Therefore, this report
focuses on alternative particulate matter (PM) emission standards.
This analysis estimates the potential environmental, cost, and energy
impacts associated with alternative PM emission regulations. These impacts
are measured in terms of the projected changes that would occur under
alternative PM emission standards versus existing regulations. The analysis
of environmental impacts focuses on changes in levels of air emissions as
well as changes in the amount of solid and liquid wastes generated. Cost
impacts are evaluated in terms of incremental changes in the total annualized
costs for boiler and pollution control equipment capital, operating, and fuel
costs. Energy impacts are evaluated in terms of potential increases in
energy consumption as a result of added PM control equipment.
This analysis examines projected impacts in the fifth year following
proposal of standards. It was assumed that the recommended standards would
be proposed in 1989 and that the impact analysis should, therefore, focus on
projected results for new small nonfossil fuel-fired boilers installed in the
5-year period between 1989 and 1993. The emissions and energy demand
projections presented in this report represent annual estimates for calendar
year 1993.
1
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This report addresses only nonfossil fuel consumption in new small
boilers. It does not analyze fossil fuel-fired steam generating units (i.e.,
coal, oil, and natural gas). The potential national impacts for fossil
fuel-fired small boilers are presented in a separate report.
A summary of the national impacts analysis is presented in Section 2.0.
Projections of the number of new wood-fired small boilers are presented in
Section 3.0. The results of the national impacts analysis are presented in
Section 4.0.
2.0 SUMMARY
To analyze the potential national impacts of PM control, the number of
small wood-fired boilers projected for both industrial and commercial-
institutional uses was estimated for the 5-year period from 1989 to 1993.
Based on recent sales data and the assumption of level sales over this
period, a total of 105 new wood-fired boilers was projected. A discussion of
the bases for the costs used in this analysis is found in Reference 2.
Four boiler sizes were examined representing small commercial-
institutional units, large commercial-institutional units, small industrial
units, and large industrial units. However, only high capacity factor (0.55)
units were examined because, according to a National Council for Air and
Stream Improvement report, most of the wood-fired boilers in these size
ranges operate at this, or higher, levels.
National Impacts
The national impacts of the PM control alternatives were estimated by
aggregating the model boiler impacts over the projected national 5-year
population of 105 new wood-fired boilers.
As shown in Table 2-1, the primary national environmental impact would
be the reduction in PM emissions from new, modified, and reconstructed small
wood-fired boilers resulting from the promulgation of NSPS. Under the
regulatory baseline, total national PM emissions from small wood-fired
boilers are estimated at 2,700 Mg/yr (2,970 tons/yr) for 1993. Under
standards based on Regulatory Alternative Level I, total national PM
emissions in 1993 are estimated at 1,650 Mg/yr (1,810 tons/yr), a 39 percent
reduction from baseline PM emission levels. Under Regulatory Alternative
2
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Level II, total national PM emissions in 1993 are estimated at 1,020 Mg/yr
(1,130 tons/yr), a 62 percent reduction from baseline PM emission levels.
Under Regulatory Alternative Level III, total national PM emissions in 1993
are estimated at 680 Mg/yr (750 tons/yr), a 75 percent decrease from baseline
PM emission levels.
The control of PM emissions from small wood-fired boilers would also
increase the amount of solid waste produced as a by-product of pollution
control, a secondary environmental impact. The amount of solid waste
generated under the baseline by pollution control devices and small
wood-fired boilers is 36,600 Mg/yr (40,350 tons/yr}. The incremental amount
of solid waste generated as a result of additional PM control would range
from 3 percent of baseline rates for Regulatory Alternative Level I to
6 percent of baseline rates for Regulatory Alternative Level III. Such
wastes are nonhazardous; environmentally acceptable methods for their
disposal are readily available.
As with national environmental impacts, projected national cost impacts
vary according to the stringency of the various regulatory alternatives.
Under the baseline, total national before-tax annualized costs for small
wood-fired boilers and PM controls in 1993 are estimated to be $103,750,000.
Under standards based on Regulatory Alternative Level I, total national
annualized PM control costs are estimated to be $105,140,000/yr, which
represents a 1 percent increase over baseline costs. Under standards based
on Regulatory Alternative Level II, total national annualized PM control
costs are estimated to be $109,900,000/yr, which represents a 6 percent
increase over baseline costs. Under standards based on Regulatory
Alternative Level III, total national annualized PM control costs are
estimated to be $113,150,000/yr, which represents an 9 percent increase over
baseline costs.
The projected national incremental cost effectiveness of the various
regulatory alternatives varies as a function of cost and emission reductions.
The estimated national incremental cost effectiveness of standards based on
Regulatory Alternative Level I over the regulatory baseline is $l,383/Mg
($l,257/ton) of PM removed. The estimated national incremental cost
effectiveness of standards based on Regulatory Alternative Level II over
Regulatory Alternative Level I is $7,103/Mg ($6,457/ton) of PM removed. The
estimated national incremental cost effectiveness of standards based on
4
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Regulatory Alternative Level III over Regulatory Alternative Level II is
$9,423/Mg ($8,566/ton) of PM removed.
Energy consumed to operate the PM control equipment is estimated to
increase only slightly under the various regulatory alternatives compared to
the baseline.
3.0 PROJECTIONS OF NEW WOOD-FIRED SMALL BOILERS
Projections of the number of new boilers expected to be built over the
5-year period from 1989 to 1993 were made using annual sales data available
for the years 1985 and 1986 from the American Boiler Manufacturers
Association (ABMA). Based on historical sales trends, it was assumed that
boiler sales would remain level over the 5-year period. The number of new
boilers expected to be built over this 5-year period was estimated for four
boiler size ranges: 0.8 to 2.9 MW (3 to 10 millionJtu/hour); 2.9 to 8.7 MW
(10 to 30 million Btu/hour); 8.7 to 15 MW (30 to 50 million Btu/hour); and 15
to 29 MW (50 to 100 million Btu/hour). These size ranges were selected based
on boiler type and the sector (i.e., industrial, commercial, or
institutional) in which the unit is found.
In the 0.8 to 2.9 MW (3 to 10 million Btu/hour) size range, only
commercial-institutional (including watertube, firetube, and firebox) units
are found. Commercial-institutional units dominate the 2.9 to 8.7 MW (10 to
30 million Btu/hour) size range, although a few industrial units are also
found. In the upper size ranges [8.7 to 15 MW (30 to 50 million Btu/hour)
and 15 to 29 MW (50 to 100 million Btu/hour)], industrial (watertube) units
predominate.
As presented in Table 3-1, new wood-fired small boilers were projected
for each of the four size ranges using an average of the 1985 and 1986 sales
data. Using the 1986 sales data for illustration, the following discussion
describes the method used to disaggregate the number of wood-fired boilers in
each of the four size ranges.
Based on the ABMA 1986 sales data for commercial-institutional units,
6,054 boilers were sold in 1986. However, this number includes boilers
firing all types of fuels. The total number of wood-fired units sold for all
size ranges, including boilers larger than 29 MW (100 million Btu/hour), was
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35. To estimate how many of these 35 wood-fired boilers were in the 2.9 to
8.7 MW (10 to 30 million Btu/hour) size range, it was assumed that the
wood-fired boilers were distributed among the various size ranges in the same
percentages as the total number of boilers sold. For example, 671 boilers in
the 2.9 to 8.7 MW (10 to 30 million Btu/hour) size range were sold. This
number is about 10 percent of the 6,054 total boilers (all sizes) sold.
Thus, the percentage of wood-fired boilers between 2.9 and 8.7 MW (10 and
30 million Btu/hour) was estimated to be about 10 percent, or four new
boilers projected per year. Applying this same methodology to the 8.7 to
15 MW (30 to 50 million Btu/hour) size range, the projected number of new
boilers is less than one per year.
The average boiler size of the four wood-fired boilers in the 2.9 to
8.7 MW (10 to 30 million Btu/hour) size range was estimated by assuming that
the average boiler size for wood-fired boilers would be the same as that for
boilers of all fuel types. Based on this assumption, the average size of a
wood-fired boiler within the 2.9 to 8.7 MW (10 to 30 million Btu/hour) size
range is about 4.2 MW (15 million Btu/hour).
The same methodology was used to estimate the number of wood-fired
boilers in the 0.8 to 2.9 MW (3 to 10 million Btu/hour) size range. As a
result, it was calculated that 11 wood-fired boilers were sold in the 0.8 to
2.9 MW (3 to 10 million Btu/hour) size range. The average boiler size was
estimated to be 1.5 MW (5 million Btu/hour).
In the ABMA 1986 sales data for large industrial boilers, boiler sales
were presented by fuel and size range. In the 2.9 to 8.7 MW (10 to
30 million Btu/hour) size range, 1 wood-fired unit was sold with a heat input
capacity of 8.7 MW (30 million Btu/hour); in the 8.7 to 15 MW (30 to
50 million Btu/hour size) range, 2 wood-fired units were sold with an average
heat input capacity size of 13 MW (45 million Btu/hour); in the 15 to 29 MW
(50 to 100 million Btu/hour) size range, 1 wood-fired unit was sold with a
heat input capacity of 22 MW (75 million Btu/hour).
The average number of industrial and commercial-institutional boilers
for 1985 and 1986 estimated in each size range is shown in Table 3-1. Sales
of both new industrial and commercial-institutional wood-fired small boilers
are projected to remain at these average levels during the 5-year period from
1989 to 1993. Therefore, 50 (10 x 5 years) small commercial-institutional
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boilers with a total heat input capacity of 860 MW (250 million Btu/hour)
are projected for the 0.8 to 2.9 MW (3 to 10 million Btu/hour) size range;
25 (5 x 5 years) industrial and commercial-institutional boilers with a total
heat input capacity of 1550 MW (450 million Btu/hour) are projected for the
10 to 30 million Btu/hour size range; 20 (4 x 5 years) industrial boilers
with a total heat input capacity of 2690 MW (780 million Btu/hour) are
projected for the 30 to 50 million Btu/hour size range; and 10 (2x5 years)
industrial boilers with a total heat input capacity of 2590 MW (750 million
Btu/hour) are projected for the 15 to 29 MW (50 to 100 million Btu/hour) size
range.
4.0 NATIONAL IMPACTS
This section presents the results of the national impacts analysis of
various regulatory alternatives limiting PM emissions from small wood-fired
boilers. Because wood is the most commonly used nonfossil fuel among small
boilers, it will be the only nonfossil fuel covered by standards developed
for this source category. Hence, the national impact analysis is based on
the impacts of regulatory alternatives for small wood-fired boilers. The
projected population of 105 new wood-fired boilers, all operating at a
55 percent capacity factor, will be used to analyze each of the regulatory
alternatives presented in Table 4-1.
4.1 ENVIRONMENTAL IMPACTS
The primary national environmental impact would be the reduction in PM
emissions from new, modified, and reconstructed small wood-fired boilers
resulting from the promulgation of NSPS. A range of PM emission reductions,
reflecting the varying degree of stringency of the regulatory alternatives
evaluated, is presented in Table 4-2.
Under the regulatory baseline, which is based on existing State and
local regulations in the absence of an NSPS, total national PM emissions from
small wood-fired boilers are estimated at 2,700 Mg/yr (2,970 tons/yr) for
1993. Regulatory Alternative Level I is an emission limit of 130 ng/J
(0.30 Ib/million Btu) based on the use of a double mechanical collection
8
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TABLE 4-1. ALTERNATIVE PM CONTROL LEVELS FOR NONFOSSIL FUEL-FIRED BOILERS4
Alternative
control
level
Baseline
A
B
C
Control
technology basis
Single mechanical collector
Double mechanical collector
Wet scrubber or electrostatic
precipitator
Wet scrubber or electrostatic
precipitator
PM emission rate
ng/J Ob/million Btu)
a
130 (0.30)
40 (0.10)
40 (0.10)
Cutoff
MW (million
Btu/hour)
8.7 (30)
8.7 (30)
2.9 (10)
260 ng/J (0.60 Ib/million Btu) for boilers larger than or equal to 8.7 MW
(30 million Btu/hour) heat input; 190 ng/J (0.45 Ib/million Btu) for
boilers smaller than 8.7 MW (30 million Btu/hour) heat input.
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(DMC) and a size cutoff of 8.7 MW (30 million Btu/hour). Total national PM
emissions in 1993 under this alternative are estimated at 1,650 Mg/yr
(1,810 tons/yr), a 39 percent reduction from baseline PM emission levels.
Regulatory Alternative Level II is an emission limit of 43 ng/J
(0.10 Ib/million Btu) based on the use of an electrostatic precipitator (ESP)
and a size cutoff of 8.7 MW (30 million Btu/hour). Total national PM
emissions in 1993 under this alternative are estimated at 1,020 Mg/yr
(1,130 tons/yr), a 62 percent reduction from baseline PM emission levels.
Regulatory Alternative Level III is an emission limit of 43 ng/J
(0.10 1 a/million Btu) based on the use of an ESP and a size cutoff of 2.9 MW
(10 million Btu/hour). Total national PM emissions in 1993 under this
alternative are estimated at 680 Mg/yr (750 tons/yr), a 75 percent decrease
from baseline PM emission levels.
The control of PM emissions from small wood-fired boilers would increase
the amount of solid waste produced as a by-product of pollution control. The
amount of solid waste generated under the baseline by pollution control
devices and small wood-fired boilers is 36,600 Mg/yr (40,350 tons/yr). The
amount of solid waste generated under standards based on Regulatory
Alternative Level I is estimated to be approximately 37,600 Mg/yr
(41,400 tons/yr) in 1993. This amount represents a 3 percent increase over
baseline rates. The amount of solid waste generated under Regulatory
Alternative Level II is estimated to be approximately 38,300 Mg/yr
(42,200 tons/yr) in 1993, which represents a 5 percent increase over baseline
rates. The amount of solid waste generated under Regulatory Alternative
Level III is estimated to be approximately 38,600 Mg/yr (42,600 tons/yr) in
1993, which represents a 6 percent increase over baseline rates. Such wastes
are nonhazardous; environmentally acceptable methods for their disposal are
readily available.
4.2 COST IMPACTS
As with national environmental impacts, projected national cost impacts
vary according to the stringency of the various regulatory alternatives. The
costs used in this analysis are based on information in Reference 5. Under
the baseline, total national annualized PM control costs for small wood-fired
11
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boilers and PM controls in 1993 are estimated to be $103,750,000. Under
Regulatory Alternative Level I, total national annualized PM control costs
are estimated to be $105,140,000/yr, which represents a 1 percent increase
over baseline costs. Under Regulatory Alternative Level II, total national
annualized PM control costs are estimated to be $109,900,000/yr, which
represents a 6 percent increase over baseline costs. Under Regulatory
Alternative Level III, total national annualized PM control costs are
estimated to be $113,150,000/yr, which represents an 9 percent increase over
baseline costs.
The projected national incremental cost effectiveness of the various
regulatory alternatives varies as a function of cost and emission reductions.
The estimated national incremental cost effectiveness of standards based on
Regulatory Alternative Level I over the regulatory baseline is $l,383/Mg
($l,257/ton) of PM removed. The estimated national incremental cost
effectiveness of standards based on Regulatory Alternative Level II over
Regulatory Alternative Level I is $7,103/Mg ($6,457/ton) of PM removed. The
estimated national incremental cost effectiveness of standards based on
Regulatory Alternative III over Regulatory Alternative Level II is $9,423/Mg
($8,566/ton) of PM removed.
4.3 ENERGY IMPACTS
Energy consumed to operate the PM control equipment is estimated to
increase only slightly under the various regulatory alternatives compared to
the baseline.
12
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5.0 REFERENCES
1. Memorandum from Aul, Jr., E. F., Radian Corporation, to Maxwell, W. H.
EPA/ISB. September 22, 1987. Population Projection for Small Mixed
Fuel-Fired Steam Generating Units.
2. Model Boiler Cost Analysis for Controlling Particulate Matter (PM)
Emissions from Small Steam Generating Units. U.S. Environmental
Protection Agency, Research Triangle Park, N.C. EPA Publication No.
EPA-450/3-89-15. May 1989.
3. Reference 1.
4. Overview of the Regulatory Baseline, Technical Basis, and Alternative
Control Levels for Particulate Matter (PM) Emission Standards for Small
Steam Generating Units. U.S. Environmental Protection Agency, Research
Triangle Park, N.C. EPA Publication No. EPA-450/3-89-11. May 1989.
5. Reference 2.
13
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before cample ting/
1. REPORT NO.
EPA-450/3-89-18
4. TITLE AND SUBTITLE PfOJeCtSd IlT
Part icu late Matter New Sourc
Industrial -Commercial -Instit
Fired Steam Genera tine Units
7. AUTHOR(S)
9. PERFORMING ORGANIZATION NAME Al»
Emission Standards Division
Office of Air Quality Plann
U.S. Environmental Protecti
Research Triangle Park, Nor
12. SPONSORING AGENCY NAME AND ADC
Office of Air Quality Plann
Office of Air and Radiation
U.S. Environmental Protecti
Research Triangle Park, Nor
2. 3. RECIPIENTS ACCESSION NO.
ipacts of Alternative ''"MaTllsT
^ Performance Standards for «<«
Utional NonfQSSil Fuel- 6. PERFORMING ORGAN.ZAT.ON CODE
8. PERFORMING ORGANIZATION REPORT NO.
iO ADDRESS 10. PROGRAM ELEMENT NO.
ing and Standards n. CONTRACT/GRANT NO.
on Agency fifl-n?-4^7fi
th Carolina 27711 58-02-4378
1RESS 13. TYPE OF REPORT AND PERIOD COVERED
ing and Standards Final
14. SPONSORING AGENCY CODE
on Agency EPA/200/04
th Carolina 27711 EPA/
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INSTRUCTIONS
•L REPORT NUMBER
Insert the EPA report number as it appears on the cover of the publication.
2. LEAVE BLANK
3. RECIPIENTS ACCESSION NUMBER
Reserved for use by each report recipient.
4. TITLE AND SUBTITLE
Title should indicate clearly and briefly the subject coverage of the report, and be displayed prominently. Set subtitle, if used, in smaller
type or otherwise subordinate it to main title. When a report is prepared in more than one volume, repeat the primary tide, aild volume
number and include subtitle for the specific title.
5. REPORT DATE
Each report shall cany a date indicating at least month and year. Indicate the hasn on which it was selected (e.g.. Jatr n) usur. date of
approval, date of preparation, etc.).
8. PERFORMING ORGANIZATION CODE
Leave blank.
7. AUTHOR(S)
Give namen i ONIUIMS a
significant bibliography or literature survey, mention it here.
17. KEY WORDS AND DOCUMENT ANALYSIS
(a) DESCRIPTORS - Select from the Thesaurus of Engineering and Scientific Terms the proper aulhuri/ed terms that identify the major
concept of the research and are sufficiently specific and precise to be used as index entries lor cataloging.
(b) IDENTIFIERS AND OPEN-ENDED TERMS - Use identifiers for project names, code names, equipment designators, etc. Use open-
ended terms written in descriptor form for those subjects for which no descriptor exists.
(c) COSATI MELD GROUP • Field and group assignments ore to be taken from the l%5 COSATI Subject Caicpory List. Since the ma-
jority of documents are multidisciplirury in nature, the Primary Field/Croup assignment^) will be specific discipline, area of human
endeavor, or type of physical object. The application**) will be cross-referenced with secondary I icld/(irou|i jsMunmcnts that will lollo-*
the primary postings).
18. DISTRIBUTION STATEMENT
Denote reieasabiliry to the public or limitation for reasons other than security for example "Release Unlimited." Cite any jvuiluhihty to
the public, with address and pncc.
19. i 20. SECURITY CLASSIFICATION
DO NOT submit classified reports to the National Technical Information service.
21. NUMBER OF PAGES
Insert the total number of pages, including this one and unnumbered pages, but exclude distribution list, il any.
22. PRICE
Insert the price set by the National Technical Information Service or the Government Printing Office, if known.
E PA Form 2220-1 (R«v. 4-77) (R«v«r»«)
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