EPA-450/3-75-067
May 1975
NEW SOURCE
CLASSIFICATION CODES
FOR PROCESSES WHICH CAUSE
HYDROCARBON AND ORGANIC
EMISSIONS
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
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EPA-450/3-75-067
NEW SOURCE
CLASSIFICATION CODES
FOR PROCESSES WHICH CAUSE
HYDROCARBON AND ORGANIC
EMISSIONS
by
Norman F. Surprenant and Mark I. Bornstein
GCA Corporation
GCA/Technology Division
Bedford, Massachusetts 01730
Contract No. 68-02-1006
Task Order 8
EPA Project Officer: Archibald MacQueen
Prepared for
ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Air Quality Planning and Standards
Research Triangle Park, N. C. 27711
May 1975
-------
This report is issued by the Environmental Protection Agency to report
technical data of interest to a limited number of readers. Copies are
available free of charge to Federal employees, current contractors and
grantees, and nonprofit organizations - as supplies permit - from the
Air Pollution Technical Information Center, Environmental Protection
Agency, Research Triangle Park, North Carolina 27711; or for a fee,
from the National Technical Information Service, 5285 Port Royal Road,
Springfield, Virginia 22161.
This report was furnished to the Environmental Protection.Agency by
GCA Corporation, Bedford, Massachusetts 01730, in fulfillment of Contract
No. 68-02-1006. The contents of this report are reproduced herein as
received from GCA Corporation. The opinions , findings , and conclusions
expressed are those of the author and not necessarily those of the Environmental
Protection Agency. Mention of company or product names is not to be
considered as an endorsement by the Environmental Protection Agency.
Publication No. EPA-450/3-75-067
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SECTION I
SUMMARY
This report is a summary of the work performed by GCA/Technology
Division for the Environmental Protection Agency under Contract No.
68-02-1006, Task Order No. 8, to develop an expanded list of Source
Classification Codes for hydrocarbon emission processes. This list is
based on knowledge of source activity gained under the following two
contracts:
• Contract 68-02-1006, Task Order No. 3, Hydrocarbon
Emission Sources in the Metropolitan Boston Intrastate
Air Quality Control Region
• Contract 68-02-1376, Task Order No. 6, Hydrocarbon
Emission Sources in Rhode Island and Southeastern
Massachusetts.
The above two contracts consisted of identifying and analyzing hydro-
carbon emission sources. The results were a prerequisite for
evaluating stationary source regulations for the development of trans-
portion control strategies.
The main objective of this program was to develop new SCC's that would
identify the types of hydrocarbon solvents used in surface coatings,
including those used for cleaning and dilution. This report does not
and was not intended to develop an exhaustive list of SCC's for all
hydrocarbon emitting point sources, but only was intended to provide
SCC's for those sources encountered in the two previously mentioned
contracts.
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SECTION II
DESCRIPTION OF THE WORK PERFORMED
The present SCC listing does not provide any suitable means of coding
the types of solvents found in paint, varnish, shellac, lacquer, primer,
or enamel. It also does not provide any information about printing
operations and the types of solvents most commonly used by the printing
industry. After carefully reviewing the information reported in the
hydrocarbon questionnaires used in the two contracts, a list of 78 new
SCC's was developed for the above classes. An additional 14 other
SCC's were developed for five other major categories:
• 3 for Textile Manufacturing
• 1 for Dry Cleaning
• 1 for Degreasing
• 3 for Coating Ovens
• 6 for Adhesives.
All 92 new SCC's are presented in Appendix A.
After receiving approval for the proposed new SCC's, CCA proceeded
to make the necessary data corrections to all point sources reported
in the above two contracts. New SCC's were assigned and the data was
keypunched into NEDS format. Approximately 300 emission points were
receded.
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EMISSION FACTORS
Emission factors for surface coatings from paints, varnishes, shellacs,
lacquers, enamels, primers, and adhesives are essentially the same.
Solvent that is found in the original coating will evaporate. There-
fore, the emission factor for a solvent within a coating is 2000 pounds
per ton of solvent within the coating. This results in the operating
rate on NEDS Card 6 becoming the emission rate.
Emission factors for printing operations, however, will vary depending
upon- the type of printing press and ink used. See Appendix B for
process description. On the average, letterpress and lithographic
printing inks contain about 35 percent solvent. Flexographic and
gravure printing inks contain approximately 65 percent solvent.
Emissions from textile manufacturing vary depending upon the type of
process and material being coated. The reader is referred to the
Encyclopedia of Polymer Science and Technology for further informa-
2
tion.
EXAMPLE PROBLEM
An example of how the new SCC's should be used is shown in the follow-
ing illustration.
An automobile manufacturer reports using 100 tons of paint and 25
tons of paint thinner. He has also stated that the paint contains
44 percent solids, 15 percent ethyl acetate, 25 percent toluene, and
the remainder an unknown solvent. He reported the thinner he is
using to be a 40-60 blend of MEK and toluene respectively.
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Using the oli NEDS SCC listing, the coding would appear as follows;
Point Source
Point Source
SCC
4-02-001-01
Evap. - Surface Coating - Paint -
General
Operating Emissions
rate (tons/year)
4-02-009-01
Evap. - Surface Coating
vent - General
4-02-001-03
100
25
- Sol-
56
25
However, using the new SCC listing it would appear as follows based upon
the example calculation shown in Table 1.
Point Source
Point Source
Point Source
Point Source
Point Source
SCC
4-02-001-03
Evap. - Surface Coating - Paint -
Ethyl acetate
4-02-001-05
Evap. - Surface Coating - Paint -
Toluene
4-02-001-99
Evap. - Surface Coating - Paint -
Solvent - General
4-02-009-18
Evap. - Surface Coating - Sol-
vent - MEK
Operating Emissions
rate (tons/year)
4-02-009-22
Evap. - Surface Coating
vent - Toluene
15
25
16
10
15
15
25
16
10
15
- Sol-
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Table 1. EXAMPLE CALCULATION
For 100 cons paint:
(44% solids)(100 tons paint) = 44 tons solids
(15% ethyl acetate)(100 tons paint) = 15 tons Ethyl acetate
(25% Toluene)(100 tons paint) = 25 tons Toluene
Total tons of known material = 84 tons
(100 tons - 84 tons) = 16 tons unknown solvent
For 25 tons thinner:'
(40% MEK)(25 tons thinner) = 10 tons MEK
(60% Toluene)(25 tons thinner) = 15 tons Toluene
REFERENCES
1. U.S. EPA. Systems and Costs to Control Hydrocarbon Emissions.
from Stationary Sources. Report No. EPA-450/2-74-006,
September 1974.
2. Encyclopedia of Polymer Science and Technology. Volume 6.
John Wiley and Sons, 1967. p 467-489.
3. Encylopedia of Polymer Science and Technology. Volume II.
John Wiley and Sons. New York, 1965.
4. Conversation with Mr. Von Forcken of Sinclair and Valentine Co.
Boston, Mass., November 1973.
5. Salomon, Gerrard, et al. A Compilation of Solvents for Flexographic
and Gravure Inks. American Inkmaker, February 1969. p. 28-38.
6. Exhaust Gases from Combustion and Industrial Processes. Engineering
Science Inc. Washington, D.C., 1971.
7. Renson, J. E. Chemical Consumption Patterns in the Printing Ink
Industry. American Inkmaker, May 1968, p 58-61.
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APPENDIX A
PROPOSED NEW SCO's
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Class I
Industrial
process
3
Point source
evaporation
4
Point source
evaporation
4
Class II
Textile
manufacturing
30
Cleaning
solvent
01
Cleaning
solvent
01
Class III
Rubberized
fabrics
002
Dry cleaning
001
Degreasing
002
Class IV
99a Other/not specified
01 Impregnation
02 Wet coating
03 Hot melt coating
01 Perchloroethylene
02a Stoddard
99 Other/not classified
06 Toluene
Factor
210
305
Units
Tons processed
Tons processed
Tons processed
Tons processed
Tons cloths
cleaned
Tons cloths
cleaned
Tons cloths
cleaned
Tons solvent
used
Already existing on SCC file
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oo
Class I
! ' ._ -.^^^^>=
evaporation
4
Point source
evaporation
A
.
Class II
Surface coating
02
Surface coating
02
Class III
Paint
001
Varnish/ shellac
003
Class IV
01 General
02 Acetone
03 Ethyl acetate
04 MEK
05 Toluene
99 Solvent general
Ola General
02 Acetone
03 Ethyl acetate
04 Toluene
05 Xylene
99 Solvent general
Factor
1120
2000
2000
2000
2000
2000
1000
2000
2000
2000
2000
2000
Units
Tons coating
Tons solvent
in coating
Tons solvent
in coating
Tons solvent
in coating
Tons solvent
in coating
Tons solvent
in coating
Tons coating
Tons solvent
in coating
Tons solvent
in coating
Tons solvent
in coating
Tons solvent
in coating
Tons solvent
in coating
Already existing on SCC file
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Class I
Point source
evaporation
4
Point source
evaporation
4
Class II
Surface coating
02
Surface coating
02
Class III
Lacquer
004
Enamel
005
Class IV
Ola General
02 Acetone
03 Ethyl acetate
04 Isopropyl alcohol
05 MEK
06 Toluene
07 Xylene
99 Solvent general
Ola General
02 Cellosolve acetate
03 MEK
04 Toluene
Factor
1540
2000
2000
2000
2000
2000
2000
2000
840
2000
2000
2000
Units
Tons coating
Tons solvent
in coating
Tons solvent
in coating
Tons solvent
in coating
Tons solvent
in coating
Tons solvent
in coating
Tons solvent
in coating
Tons solvent
in coating
Tons coating
Tons solvent
in coating
Tons solvent
in coating
Tons solvent
in coating
Already existing on SCC file
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Class I
Point source
4
Point source
evaporation
4
Point, source
evaporation
4
Class II
Surface coating
02
Surface coating
02
Surface coating
02
Class III
Enamel
005
Primer
006
Adhesive
007
Class IV
05 Xylene
99 Solvent general
Ola General
02 Naphtha
03 Xylene
04 Mineral spirits
05 Toluene
99 Solvent general
01 General
02 MEK
03 Toluene
Factor
2000
2000
1320
2000
2000
2000
2000
2000
2000
2000
Units
Tons solvent
in coating
Tons solvent
in coating
Tons coating
Tons solvent
in coating
Tons solvent
in coating
Tons solvent
in coating
Tons solvent
in coating
Tons solvent
in coating
Tons coating
Tons solvent
in coating
Tons solvent
in coating
Already existing on SCC file
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Class I
Point source
evaporation
4
Point source
evaporation
4
Point source
evaporation
4
Class II
Surface coating
02
Surface coating
02
Surface coating
02
Class III
Adhesive
007
Coating oven
008
Solvent
009
Class IV
04 Benzene
05 Naphtha
99 Solvent general .
Ola General
02 Dried, < 175°F
03 Baked, > 175°F
99 Other/not classified
01 General
02 Acetone
03 Butyl acetate
04 Butyl alcohol
05 Carbitol
06 Cellosolve
07 Cellosolve acetate
08 Dimethyl-formamide
Factor
2000
2000
2000
2000
2000
. 2000
2000
2000
2000
2000
2000
Units
Tons solvent
in coating
Tons solvent
in coating
Tons solvent
in coating
Tons coating
Tons coating
Tons coating
Tons coating
Tons solvent
Tons solvent
Tons solvent
.Tons solvent
Tons solvent
Tons solvent
Tons solvent
Tons solvent
Already existing on SCC file
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Class I
Point source
evaporation
4
Point source
evaporation
• 4
Class II
Surface coating
02
!
1
1
i
|
Printing press
05
Class III
Solvent
009
i
Letterpress
002
Class IV
09 Ethyl acetate
10 Ethyl alcohol
11 Gasoline
12 Isopropyl alcohol
13 Isopropyl acetate
14 Kerosene
15 Lactol spirits
16 Methyl acetate
17 Methyl alcohol
18 MEK
19 MIBK
20 Mineral spirits
21 Naphtha
22 Toluene
23 Varsol
24 Xylene
01 General
02 Kerosene
03 Mineral spirits
99 Solvent general
Factor
2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
700
2000
2000
2000
Units
Tons solvent
Tons solvent
Tons solvent
Tons solvent
Tons solvent
Tons solvent
Tons solvent
Tons solvent
Tons solvent
Tons solvent
Tons solvent
Tons solvent
Tons solvent
Tons solvent
Tons solvent
Tons solvent
Tons ink
Tons solvent
in ink
Tons solvent
in ink
Tons solvent
in ink
Already existing on SCC file
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u>
Class I
Point source
evaporation
4
Point source
evaporation
4
Class II
Printing press
05
Printing press
05
Class III
Flexographic
003
Lithographic
004
Class IV
01 General
02 Carbitol
03 Cellosolve
04 Ethyl alcohol
05 Isopropyl alcohol
06 N-propyl alcohol
07 Naphtha
99 Solvent general
01 General
02 Mineral spirits
03 Isopropyl alcohol
99 Solvent general
Factor
1300
2000
2000.
2000
2000
2000
2000
2000
700
2000
2000
2000
Units
Tons ink
Tons solvent
in ink
Tons solvent
in ink
Tons solvent
in ink
Tons solvent
in ink
Tons solvent
in ink
Tons solvent
in ink
Tons solvent
in ink
Tons ink
Tons solvent
in ink
Tons solvent
in ink
Tons solvent
in ink
Already existing on SCC file
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Class I
Point source
evaporation
4
Class II
Printing press
05
•
1'
.
i
!
Class III
Gravure
005
Class IV
01 General
02 Dimethyl-formamide
03 Ethyl acetate
04 Ethyl alcohol
05 Isopropyl alcohol
06 MEK
07 MIBK
08 Mineral spirit's
09 N-propyl alcohol
10 Toluene
99 Solvent general
Factor
1300
2000
2000
2000 .
2000
2000
2000
2000
2000
,2000
2000
Units
Tons ink
Tons solvent
in ink
Tons solvent
in ink
Tons solvent
in ink
Tons solvent
in ink
Tons solvent
in ink
Tons solvent
in ink
Tons solvent
in ink
Tons solvent
in ink
Tons solvent
in ink
Tons solvent
in ink
Already existing on SCC'file
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APPENDIX B
DESCRIPTION OF PRINTING OPERATIONS
15
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DESCRIPTION OF PRINTING OPERATIONS
There are four main types of printing operations; letterpress,
lithographic, flexographic and gravure.
Letterpress, the oldest printing process, is defined as printing from
raised type. The process is based on the simple stamping principle
and produces a high quality of print on almost any type of paper or
board. There are essentially three types of letterpresses in commercial
use; platen, flat-bed and'web rotary. Platen presses can print a
variety of jobs, from a simple one-color to multicolor. The flat-bed
press is widely used in printing catalogs, books and booklets. The web
rotary press consists of two cylinders, one for the plate and the
other for impression. This equipment is capable of very high speeds
and is used for publications, packaging and commercial printing.
Lithographic printing is based on the principal of oil and water
immiscibility. The level printing surface is prepared chemically
resulting in the image area accepting oleophilic ink and the nonprint-
ing area accepting water. Lithography has many advantages. Plate
making is simple, fewer mechanical operations are required and it is
economical for short runs.
Flexographic printing is a special form of relief printing. A
flexible typographic rubber plate is mounted on a cylinder and is
used to transfer the lacquer-type ink. This type of operation allows
printing on hard surfaces, such as plastic films, calendered papers
and metallic foils. Equipment for flexographic printing is divided
into two classes; stack presses and common-impression equipment. In
stack presses each color has its own unit consisting of fountain,
roller, plate cylinder and impression cylinder. In common-impression,
one large cylinder is used for several printing units, and is
particularly useful for the decoration or plastic films.
16
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Gravure printing utilizes a recessed surface for transferring the
lacquer-type ink. It is the only process in which the ink film
does not contact a flexible synthetic roller. Gravure ink is instant
drying and the polymers must be preformed to be useful. The resins
must be. tack.-free and have excellent solvent release properties. Unlike
other printing processes, the pressure is not transmitted through the
ink film; instead it is only on the cyclinder plate, impression roller
and substrate.
Certain types of inks are used with certain methods. Table 2 indicates
the range of percent solvent content in inks for two drying methods
versus the four printing processes.
4,5,6
Table 2. PERCENTAGE OF SOLVENT CONTENT FOR TWO DRYING
METHODS VERSUS FOUR PRINTING PROCESSES
Drying
method
Evaporation
Heat set
Letter-
press
—
-10%
Flexographic
Solvent base (40-75%)
Water base (0-30%)
Litho-
graphic
—
-16%
Gravure
40-75%
—
The flexographic and gravure process account for approximately one-third
of all inks used. They mainly use solvent-based inks containing 40 to
75 percent solvent, which is then evaporated on drying. Water-base inks
are also coming into use in the flexographic process. Some of these
water-base inks also contain solvent (0 to 30 percent) for faster drying.
The screen process uses oil and lacquer-type inks which contain 0 to 60
percent solvents. However, this class accounts for less than 6 percent
of the national total solvent used for inks. Letterpress and litho-
graphic inks, which account for about one-third of the total inks used,
are oil-based and emit some solvents when heat-set letterpress or heat-
set web offset is used. Alcohol type solvents are also used in the
water fountain for the lithographic process. > > » »
17
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National total solvent used, which is also the amount emitted, for
inks, has been estimated for 1967 to be 170,000,000 Ib. Applying the
accepted annual growth rate of 7 percent for flexogravure, the solvent
o
usage breakdown is given in Table 3 for 1967 and 1972.
Table 3. NATIONAL SOLVENT USAGE
(tons/year)
Solvents
Oil inks
Flexographic/gravure
Other
1967
25,000
55,000
5,000
1972
35,000
77,000
7,000
Oil inks are mostly used in publications of periodicals and books and
in commercial printing, SIC 272 to 275. Flexographic and gravure
printing is mostly used in industries making miscellaneous converted
paper products and paperboard containers (SIC 264 and 265).
18
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Gravure print;ing utilizes a recessed surface for transferring the
lacquer-type ink. It is the only process in which the ink film
does not contact a flexible synthetic roller. Gravure ink is instant
drying and the polymers must be preformed to be useful. The resins
must be tack free and have excellent solvent release properties. Unlike
other printing processes, the pressure is not transmitted through the
ink film; instead it is only on the cyclinder plate, impression roller
and substrate.
Certain types of inks are used with certain methods. Table 2 indicates
the range of percent solvent conten
versus the four printing processes.
the range of percent solvent content in inks for two drying methods
4,5,6
Table 2. 'PERCENTAGE OF SOLVENT CONTENT FOR TWO DRYING
METHODS VERSUS FOUR PRINTING PROCESSES
Drying
method
Evaporation
Heat set
Letter-
press
—
-10%
Flexographic
Solvent base (40-75%)
Water base (0-30%)
Litho-
graphic
—
-16%
Gravure
40-75%
—
The flexographic and gravure process account for approximately one-third
of all inks used. They mainly use solvent-based inks containing 40 to
75 percent solvent, which is then evaporated on drying. Water-base inks
are also coming into use in the flexographic process. Some of these
water-base inks also contain solvent (0 to 30 percent) for faster drying.
The screen process uses oil and lacquer-type inks which contain 0 to 60
percent solvents. However, this class accounts for less than 6 percent
of the national total solvent used for inks. Letterpress and litho-
graphic inks, which account for about one-third of the total inks used,
are oil-based and emit some solvents when heat-set letterpress or heat-
set web offset is used. Alcohol type solvents are also used in the
water fountain for the lithographic process. ' ' ' '
17
-------
National totrl solvent used, which is also the amount emitted, for
inks, has be, n estimated for 1967 to be 170,000,000 lb. Applying the
accepted annual growth rate of 7 percent for flexogravure, the solvent
Q
usage breakdown is given in Table 3 for 1967 and 1972.
Table 3. NATIONAL SOLVENT USAGE
(tons/year)
Solvents
Oil inks
Flexographic/gravure
Other
1967
25,000
55,000
5,000
1972
35,000
77,000
7,000
Qil inks are mostly used in publications of periodicals and books and
in commercial printing, SIC 272 to 275. Flexographic and gravure
printing is mostly used in industries making miscellaneous converted
paper products and paperboard containers (SIC 264 and 265).
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-450/3-75-067
3. RECIPIENT'S ACCESSIOWNO.
4. TITLE AND SUBTITLE
New Source Classification Codes For Processes Which
Cause Hydrocarbon and Organic Bnissions
5. REPORT DATE
May 1975
6. PERFORMING ORGANIZATION CODE
'. AUTHOR(S)
8. PERFORMING ORGANIZATION REPORT NO.
Norman F. Surprenant
Mark I. Bernstein
9. PERFORMING ORGANIZATION NAME AND ADDRESS
GCA Corporation
GCA/Technology Division
Bedford, Massachusetts 01730
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-02-1006, Task Order 8
12. SPONSORING AGENCY NAME AND ADDRESS
U. S. Environmental Protection Agency
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
13. TYPE OF REPORT AND PERIOD COVERED
Final
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
16. ABSTRACT
This report is a summary of the work performed on two contracts which consisted
of identifying and analyzing hydrocarbon emission sources. The results were a pre-
requisite for evaluating stationary source regulations for the development of trans-
portation control strategies.
The main objective of this program was to develop new SCC's that would identify
the types of hydrocarbon solvents used in surface coatings, including those used for
cleaning and dilution. This report does not and was not intended to develop an
exhaustive list of SCC's for all hydrocarbon emitting point sources, but only was
intended to provide SCC's for those sources encountered in the two previously
mentioned contracts.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS C. COSATI Field/Croup
Emission Sources
Source Classification Codes
Hydrocarbon
Solvents
Point Sources
Emission Factors
13. DISTRIBUTION STATEMENT
Pelease Unlimited
19. SECURITY CLASSr/Vj/s Report)
. SECURITY CLASSr/Vj/
unclassified
21. NO. OF PAGES
20. SECURITY CLASS (Tills page)
IMclassified
22. PRICE
EPA Form 2220-1 (9-73)
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