Outotec Courier® SL state-of-the-art on-line analyzers offer unrivalled sensitivity and short cycle times for process management, monitoring and control in all types of mineral processing plants. Outotec is the leading supplier of advanced process automation systems, control solutions, and intelligent instruments to the mineral and metal processing industries. Our proven systems have been installed at more than 1,000 plants worldwide.

OUTOTEC COURIER SL ON-LINE ANALYZERS

BENEFITS• Consistent, reliable automated

sampling and analysis around the clock• Reduced assaying and sampling costs• Improved recovery through early

detection of process disruptions• Better control over concentrate quality

and process variations• Easy to upgrade and expand to meet

changing plant requirements

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Rapid, accurate assaying improves your responsivenessThe fast, accurate assaying provided by Outotec Courier on-line analyzers allows you to react immediately to changes in the metallurgical performance of the flotation circuit while simultaneously monitoring the effect of your actions in real time.

The frequent manual sampling, sample preparation, and laboratory assays required for 24/7 real-time process control is prohibitively expensive in terms of both manpower and equipment.

Assays based on strongly filtered or averaged measure-ments over a long period cannot be used for efficient process control. A long time delay between actual process changes and the control action makes feedback control unstable and reported process trends misleading.

WHY CHOOSE OUTOTEC COURIER ANALYZERS?• Sampling and analysis are performed

automatically and consistently around the clock, which reduces costs associated with assaying and metallurgical sampling.

• Recovery levels are improved because process disruptions are detected early and can be solved quickly. Real-time process monitoring and control requires frequent assays.

• Concentrate quality is controllable and undesirable variations are minimized.

• Plant operation is optimized, with smaller circulating loads resulting in higher throughput.

• Assay accuracy is comparable with a routine manual-sample laboratory procedure, taking into account sampling and sample preparation. Outotec Courier analyzers use the same wavelength dispersive X-ray fluorescence (WDXRF) technology as high-performance laboratory analyzers.

• Results from process tests and changes are available more quickly, which means more rapid process development.

• Due to the modular analyzer system design, it is easy to upgrade and expand the system as plant requirements change.

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Outotec Courier analyzers provide up-to-date information about your plant’s metallurgical performance by analyzing the metal content in all critical process streams. This information can be used to optimize the operation of each individual part of the flotation circuit and thereby maxi-mize your production efficiency.

Flash flotation controlMany grinding circuits include a flash flotation stage. Monitoring the flash concentrate grade helps to ensure the production of high-grade concentrate that is easy to clean or mix directly with final concentrate. This gives a significant improvement in overall recovery.

Rougher controlWhen the rougher section is working properly, the rest of the flotation circuit is much easier to run. Roughers should produce optimal-grade rougher concentrate with an acceptable recovery.

Monitoring rougher tails is key to recovery control. If the rougher tail grade is too high, there is often insufficient scavenger circuit capacity to prevent a recovery loss.

Concentrate grade is controlled by flotation cell air, level, and reagents. The optimal grade depends on the feed grade, mineralogy, circulating loads, and cleaner capacity. On-line analysis provides vital information for optimizing rougher concentrate production.

Cleaner controlIn cleaner control, the first priority is to monitor final concentrate quality. Monitoring circulating loads is also critical to maintaining high overall throughput. The Outotec Courier system is able to measure low assays of penalty elements in the presence of a high main element concentrations to ensure consistent production of the high quality concentrate.

Scavenger controlIf rougher tails are already controlled based on the assays from the Outotec Courier system, there will be lower valu-able metal contents in scavenger tails.

Measuring lower metal contents requires a highly sensi-tive analyzer. Accurate measurement of the tails assay will help to prevent valuable metal being lost, thereby maxi-mizing recovery.

COMPLETE FLOTATION CONTROL THAT MAXIMIZES EFFICIENCY AND QUALITY

Illustration of flotation plant flowsheet

Finalconcentrate

Middlingtails

Scavengertails

Roughertails

Rougherfeed

Cleanertails

Rougherconcentrate

Primaryrougherconcentrate

Mainfeed

Flotationtails

Scavengerconcentrate

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OUTOTEC COURIER SLURRY ANALYZER SYSTEMPrimary samplingA representative primary sample of the process stream is sent to the multiplexer for secondary sampling. We have a range of proven primary samplers for various process designs. Because Outotec Courier analyzers only require a low head, gravity is usually sufficient for transporting sample flows, eliminating the need for pumping. Small process flows can be fed through the analyzer’s secondary sampling system without primary samplers.

Depending on the process requirements, the primary sample flow can be continuous, with or without periodic automatic flushing. Alternatively, the sample flow can be stopped and the delivery line flushed automatically between samples. This improves sample availability when the process stream contains waste, coarse parti-cles, or material that sticks to pipe surfaces. Controlled primary sampling is a standard feature in Outotec Courier analyzers.

Secondary samplingThe full primary sample flow is switched between the bypass and level-controlled analyzer feed tanks by a two-way, air-cylinder-actuated sample hose. The same cylinder moves the hose in the opposite direction across a cutter at programmable intervals in order to collect a representative composite sample. Trash is removed from the samples by self-cleaning screens, and entrained air is minimized in a level-controlled constant-head feed tank. The tank provides a stable sample flow to the analyzer flow cell. Primary sample availability and flow rate are monitored for diagnostic purposes.

The multiplexer unit receives up to six sample streams and takes one at a time for analysis. While a sample in one multiplexer is being measured, the next is already being conditioned in the second multiplexer unit. This allows a fast measurement cycle for all streams. The measurement sequence is fully programmable – for example, critical streams can be measured more frequently and more measurement time can be used for low-grade tailings streams.

The switching time between samples is used for internal reference measurements, which are used for monitoring and automatic drift compensation. Automatic reference measurement provides instrument stability and self- diagnostics.

Optional demultiplexing can be used to divert the meas-ured small analyzer flow cell slurry flow to the appro-priate location.

The built-in calibration sampler allows the operator to take a truly representative and repeatable sample from the slurry for comparative laboratory assays.

Analyzer controlThe sampling and analyzer cabinet houses interface and control modules for primary and secondary sampling system monitoring and control.

The analyzer’s local user interface panel features a high-resolution touch screen that displays the most recent assays and assay trends, as well as sample line and analyzer status. It is also used for setting up the func-tions and parameters of the analyzers.

Composite samples

Calibration samples

Flow cell25 l/min

Fast loop70-300 l/min

Process Primarysampling

Secondary samplingMultiplexingScreeningDe-aeration Analysis

Monitoring & control

Illustration of a sampling system.

Assay trends on local operator interface display.

Display for operational status of each sample line.

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AssayingThe Courier 6X and 5X SL analyzer probes combine the high-performance wavelength and energy-dispersive X-ray fluorescence methods in a unique and cost-effective way.

To enable installation into the process environment, the analyzer probe houses the core analytical components, in an IP56-rated (NEMA 4X-compliant) stainless steel enclosure.

Courier 6X SL high-power analyzerThe Outotec Courier 6X SL is a high-performance on-line XRF analyzer for the real-time assaying a maximum of 24 slurry process streams. It offers unrivalled sensitivity and short cycle times for process management, monitoring, and control in all types of mineral processing plants.

Courier 5X SL medium-power analyzerThe Outotec Courier 5X SL is designed for accurate and reliable on-line X-ray fl uorescence (XRF) measurement of element concentrations in slurries for up to 12 sample streams at normal concentration levels. Having a lower-power X-ray tube than the Outotec Courier 6X, it can use smaller power supplies and a Peltier cooling system.

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SAMPLE PRESENTATION, ANALYSIS, AND CONTROL

Sample presentationPatented JetCell™ technology ensures that a representa-tive fresh sample is always presented for assaying at the window surface. The flow cell window is changed regu-larly to ensure it is clean and free of scaling caused by active slurry contact. Outotec’s unique Automatic Window Changer (AWC) option provides higher analyzer availa-bility and reduces the manual labor required for window changing.

AnalysisThe Outotec Courier analyzer excites the sample in the flow-cell by X-rays generated in a high-intensity X-ray tube. Atoms in the sample react by emitting fluorescence radiation characteristic of each individual element in the sample.

Outotec Courier 6X and 5X SL analyzers use high-resolution wavelength-dispersive analyzer technology for critical assays. Complementary energy-dispersive technology can be used to increase the number of elements analyzed to 12 assays per stream.

Analyzer system controlThe primary and secondary sampling system and analyzer measurements are controlled by the main controller. The multiplexer and primary sampling connect distributed I/O stations which are managed by the main controller. Addi-tional I/O stations can easily be added later if the system needs to be expanded.

X-ray fluorescence (XRF) analysis of slurry samplesIn a slurry, fluorescent X-rays from light elements are attenuated strongly. This makes on-line analysis of elements lighter than calcium (Ca) impractical. Flow cell technology enables the analysis of heavier elements as the fresh representative sample is brought right onto the surface of the measurement cell window.

1 mm sensitivelayer

Sample out

Jet flow cell

Controlled turbulentflow in the sensitive layerprovides a representative

sample and prevents scaling.

50 µ thickwindow

WDXRF channel

Signalprocessing

X-ray tube

Detector

Detector

Main controller

Automatic

reference

shutter

Spectrometer

EDXRF channel

Filter I/O Station

Sample in 25 l/min

ANALYZERNETWORK

LOCAL USER INTERFACE (CLI)

Eth Switch

Signalprocessing

Eth Switch

AUTOMATIONSYSTEM

COOLING AND TEMPERATURE CONTROL (CCA)

ANALYZER PROBE (PRS)

SAMPLING

SAMPLING CONTROL (PCS)

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57 58 59 60 61 62 63 64 65 66 67 68 69 70 71

89 90 91 92 93 94 95 96 97 98 99 100 101 102 103

104 105 106 107 108 109 110 111 112 113 114 115 116 117 118

H

Li Be

Na Mg

K Ca Sc Ti V Cr Mn Fe Co Ni Cu Zn Ga

Al

B

Ge

Si

C

As

P

N

Se

S

O

Br

Cl

F

Kr

Ar

Ne

He

Rb Sr Y Zr Nb Mo Tc Ru Rh Pd Ag Cd In Sn Sb Te I Xe

Cs Ba Hf Ta W Re Os Ir Pt Au Hg Tl Pb Bi Po At Rn

Fr Ra

La Ce Pr Nd Pm Sm Eu Gd Tb Dy Ho Er Tm Yb Lu

Ac Th Pa U Np Pu Am Cm Bk Cf Es Fm Md No Lr

Rf Db Sg Bh Hs Mt Ds Rg Cn Uut Fl Uup Lv Uus Uuo

Hydrogen

Lithium Beryllium

Sodium Magnesium

Potassium Calcium Scandium Titanium Vanadium Chromium Manganese Iron Cobalt Nickel Copper Zinc Gallium

Aluminum

Boron

Germanium

Silicon

Carbon

Arsenic

Phosphorus

Nitrogen

Selenium

Sulfur

Oxygen

Bromine

Chlorine

Fluorine

Krypton

Argon

Neon

Helium

Rubidium Strontium Yttrium Zirconium Niobium Molybdenum Technetium Ruthenium Rhodium Palladium Silver Cadmium Indium Tin Antimony Tellurium Iodine Xenon

Cesium Barium Hafnium Tantalum Tungsten Rhenium Osmium Iridium Platinum Gold Mercury Thallium Lead Bismuth Polonium Astatine Radon

Francium Radium

Lanthanum Cerium Praseodymium Neodymium Promethium Samarium Europium Gadolinium Terbium Dysprosium Holmium Erbium Thulium Ytterbium Lutetium

Actinium Thorium Protactinium Uranium Neptunium Plutonium Americium Curium Berkelium Californium Einsteinium Fermium Mendelevium Nobelium Lawrencium

Rutherfordium Dubnium Seaborgium Bohrium Hassium Meitnerium Darmstadtium Roentgenium Copernicium Ununtrium Flerovium Ununpentium Livermorium Ununseptium Ununoctium

X-ray fluorescence enables the analysis of heavier elements. Laser-induced breakdown spectroscopy can be used for analysis of lighter elements.

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Wavelength-dispersive technology (WDXRF)Wavelength-dispersive detection is used by high-perfor-mance laboratory analyzers. The wavelength-dispersive detection channel measures only the narrow element peak as illustrated in the fi gure on the right. A high-reso-lution spectrometer separates the peak corresponding the element of interest. Nearby element peaks do not overlap and the background signal is minimal. Because the full capacity of the detector is used for the relevant peak only, a high-power X-ray tube can be used, and analysis speed and sensitivity are high. Several element-specifi c, wave-length-dispersive channels are used in Outotec Courier analyzers to allow the simultaneous measurement of all elements of interest.

Energy-dispersive technology (EDXRF)The energy-dispersive detection channel is based on a solid-state detector that measures the whole spectrum. Measuring a small Zn peak (green arrow in the fi gure on the right) can be challenging since most of the detected counts cannot be used for the specifi c assay. Limited resolution usually impair the useful X-ray intensity. Analysis speed and sensitivity are low. Energy-dispersive detectors can be used for less critical measurements of high-grade assays, as a cost-effective complement to wavelength-dispersive detectors. One energy-dispersive detector can measure several element peaks simultaneously.

Improved analysis performanceIntegrated preamplifi er digital signal processing hardware gives superior signal-to-noise ratio, enabling better analysis performance in low element concentrations. In addition, measurement of higher pulse frequencies are possible, which widens the dynamic range of analyzed concentrations. High concentrate grades in the presence of wide solid content variation and low tailings grades can both be measured accurately using the same setup.

Outotec Courier 8 SL on-line analyzer In some applications, measurement of light elements such as silicon (Si), carbon (C), or sulfur (S) is benefi cial. For these types of applications we offer the Outotec Courier 8 SL light-element slurry analyzer – an on-stream analyzer based on the laser-induced breakdown spectroscopy (LIBS) measurement principle. It is capable of measuring all elements starting from lithium (Li). Although the Outotec Courier 8 SL can be used to measure heavier elements such as iron (Fe) and copper (Cu), it will not be as accurate as XRF-based analyzers like the Outotec Courier 5X SL and 6X SL. Our experts can support you in choosing the most appropriate analyzer for your application.

Scatter

Wavelength-dispersive channel WDXRF, 0.12% Zn.

Energy-dispersive channel EDXRF, 0.12% Zn.

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NETWORK OF ANALYZERS, APPLICATIONS, AND PROCESS INFORMATION

The beneficiation unit processes are closely interde-pendent - for instance, the grinding circuit affects flotation circuit performance. In order to enable plant-wide process optimization, the new generation of Outotec Courier X SL analyzers connects seamlessly with other Outotec analyzers and any plant automation system.

A comprehensive toolbox for plant metallurgists The Outotec Courier analyzer is not only a measurement instrument, but also a general-purpose toolbox for plant managers and metallurgists. All process information available in the plant automation system can be read by the Courier analyzer if desired. This provides the oppor-tunity to expand the functionality of the analyzer through additional application modules available from Outotec.

Advanced functionalities for grade-recovery optimizationThe primary purpose of an on-line analyzer is to provide information for process control. Typically, the flotation process is controlled using on-line analyzer measure-ments by introducing set-point changes in the plant control system. Advanced process control (APC) systems, integrated into plant control, are increasingly being used for this purpose.

The new generation of Outotec Courier analyzers provide APC functionality as a module for grade-recovery optimi-zation. It performs a preconfigured control strategy for flotation circuit optimization. The approach is similar to that used in Outotec ACT optimizing control applications.

Process

PSI 300/500Particle size

analyzer

Courier 5/6Sampling

and analyzercontrol

Local userinterface

Analyzerprobe

Courier remoteUI for processenvironment

Courier 8Sampling

and analyzercontrol

Local userinterface

Courier 8analyzer

probe

Outotec rem

ote support

Control room

Encrypted virtualprivate network

PC UI forremote support

Plant officenetwork

Offices

PC UIs for laboratory, instrumentshop and office environment

Plantautomation

system

PC UI forcontrol room

Firewall with anti-virus engine

Analyzer network

Automation system connections

On-line recovery calculation moduleThe metal recoveries of minerals processing plants are typically calculated using composite shift sample assays done in an on-site metallurgical laboratory. These meas-urements give the most accurate indication of the plant’s steady-state metallurgical performance. However, in some cases it may be useful to have a real-time indica-tion of the plant’s current recovery. The Outotec Courier analyzer also includes a module for the calculation of real-time recovery utilizing mass-balance reconciliation.

Improved calibrationOutotec Courier requires minimum calibration since it is based on direct measurement of element contents, just like laboratory methods are. To achieve faster ramp-up times, Outotec has developed a calibration service module that enables initial calibration of the analyzer even before the process itself is running.

Outotec Outocal™ calibration software has an intuitive user interface that makes it easier to learn and use cali-bration workflow. The web browser-based tool enables management of calibration data and calculation of the optimal calibration models used in Outotec Courier analyzers. Network connectivity allows calibration support services to be provided by Outotec experts locally or remotely.

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The Outotec Courier analyzer collects information about current performance of the fl otation circuit, for example on-line recovery. Particle size distribution in fl otation feed measured by Outotec particle size analzyers has signifi cant impact on mineral liberation and thus fl otation recovery. Laboratory assays collected by Courier analyzer calibration and composite samplers provide essential information for analyzer accuracy follow-up and metallur-gical accounting of the plant.

Traditionally process information from different sources has been scattered to different information management systems thus making analysis and synthesis of the data inconvenient. The Courier X system provides a single point where all essential process information can be accessed for further analysis.

Statistics and data analysis toolboxExploring relationships between parameters affecting the fl otation circuit is not a straightforward task due to the presence of several interrelated variables. Tools like Microsoft Excel lack features that are useful for the anal-ysis and visualization of plant performance data.

On the other hand, full-featured statistical software can be complicated to use and have a steep learning curve.

The data analysis toolbox available in the Outotec Courier X system includes features that are commonly used for analyzing problems related to the performance of the fl otation circuit – for example, studying the location of grade-recovery curve.

Continuous developmentThe Courier X system provides a fl exible way to develop new features that add value for analyzer users. It gives you the opportunity to take advantage of the latest features and developments in analysis technology as soon as they become available.

Upgrading your existing analyzers with SmartBoxThe Outotec SmartBox upgrade allows you to take advan-tage of the latest modular features and applications with previous-generation analyzers such as Courier 5/6i SL and Courier 5/6 SL.

FROM PROCESS INFORMATION TO PROCESS KNOWLEDGE

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The specifications given in this brochure are for a typical configuration and project scope. Actual scope and perfor-mance data will vary according to individual plant and project specifications, as well as the chosen

SPECIFICATIONS

MXAMultiplexer

VFUCompositesamplefiltering

PCSProbe andsamplingcontrol

DMADe-multiplexer

1900

max

imum

330

090

0

Sample return

5000

Process flowby gravity

MSA sampler

CLILocal userinterface

2100

min

imum

free

hei

ght

leak-proof ceiling

PSAsampler

Process flowby pressure

Water

LSA sampler

Process flowby gravity

Water

VFUCompositesamplefilter

MXAMultiplexer

De-multiplexer

1900

Sample return

6000Process flowby pressure

Process flowby gravity

1200

PRS Analyzerprobe

CLILocal userinterface

PCSProbe andsamplingcontrol

Secondary sample pump

adju

stab

le 1

860-

2060

PSAsampler

Water

LSA sampler

Water

product configuration. Please refer to individual product datasheets and installation manuals for more information.

11

Analysis methodThe wavelength-dispersive X-ray fluorescence (WDXRF) method uses X-ray tube excitation. Energy-dispersive chan-nels are available. Because no radioactive isotope sources are used, exposure, fire, and disposal risks are minimized.

Number of sample streamsAn Outotec Courier 6X SL analyzer system can measure up to 24 sample streams (Courier 5X SL 12 streams). Each multi-plexer module can handle up to six sample streams.

Number of simultaneous assaysOutotec Courier 5X and 6X SL analyzers can provide up to 12 simultaneous assays for elements from calcium to uranium (atomic numbers 20 to 92) and solids content from each process sample. Assay calculation models can be automati-cally switched according to changing mineralogy.

Sample measurement timeThe sample measurement time is adjustable for each sample, with the typical time being 15–30 seconds (Courier 5X SL 60 seconds).

Analysis cycleThe normal analysis cycle for 12 samples is 12 minutes, and 16 minutes for 18 streams (13–16 minutes for 12-stream Courier 5X SL), depending on the measuring time for each sample. Assays are calculated and reported based on freshly measured data for true real-time analysis.

Measurable concentration rangeFor slurries, the typical measurable concentration range is 0.001–100% by weight.

StabilityThe analyzer’s short-term stability under the specified condi-tions is better than 0.1% relative. Automatic internal refer-ence measurements compensate for long-term drift.

Minimum detection limitThe WDXRF-measurement channel’s detection limit is 3–30 ppm for most elements in slurry samples. For the ener-gy-dispersive X-ray fluorescence (EDXRF) measurement channel the minimum detection limit is typically 100–500 ppm.

AccuracyOutotec’s accuracy specification is based on the measure-ment of flowing slurry samples using measurement times for real applications. Briquette measurements and long measurement times give unrealistic results. Measurement accuracy is a function of sample parameters such as matrix composition, mineralization, and particle size. Typically, under normal operating conditions, a 3–6% relative standard deviation for minor concentrations and a 1–4% relative standard deviation for major concentrations is achieved for individual slurry sample measurements of concentration levels well above the minimum detection limit.

CalibrationAn integrated calibration sampler takes a repeatable and representative sample for analyzer calibration. Outotec Outocal software is available for interactive calibration model design.

MaintenanceOutotec Courier 5X and 6X SL analyzers are designed to be low maintenance. The analyzer probe window can be changed automatically with the Outotec AWC option. The analyzer system has built-in self diagnostics and remote diagnostics capabilities. We also offer preventive and corrective mainte-nance services, as well as training for operators.

Installation requirementsOutotec Courier 5X and 6X SL analyzers can be installed on one (low–head) or two levels. The analyzer must be located away from direct sunlight, preferably in a prefabricated shelter.

Flushing waterSand-filtered raw water, 2–6 bar (30–85 psi) average 30 l/min (8 gal/ min) peak 100 l/min (26 gal/min).

Instrument airPressure 5–10 bar (75–145 psi) 16 l/min (0.6 norm cu ft/min) average consumption.

Power supplySingle phase AC, 230 V +10%, -15% at 10 A 50/60 Hz or 115 V ±10% at 20 A 50/60 Hz. Double conversion 3 kW UPS required, 10 minutes minimum (Courier 5i SL 1200 W).

Operating ambient temperature at sea level+5…+45 °C (41…113 °F), no condensation. Temperature control is based on an air-cooled chiller. (Courier 5X SL Peltier cooler). Local and remote operator interfaces up to + 32 °C with cooling option up to +45 °C ambient temperature.

Storage temperature-25…+60 °C (-13…140 °F).

Environmental classificationAnalyzer multiplexers, probe, and probe control set: IP56 (NEMA 4X-compliant).

Shipping and installed weightThe typical total shipping weight is 1000 kg (2200 lbs) for a 12-stream system and 1250 kg (2750 lbs) for an 18-stream system. Each 6-stream multiplexer unit weighs 225 kg (500 lbs). Primary samplers and sample transportation are not included in the above weights.

ISO 9001 quality assuranceOutotec is an ISO 9001 certified company and maintains a rigorous quality management policy. Outotec Courier analyzers are certified according to the EMC, LVD, and MD directives.

Outotec provides leading technologies and services for the sustainable use of Earth’s natural resources. As the global leader in minerals and metals processing technology, we have developed many breakthrough technologies over the decades for our customers in metals and mining industry. We also provide innovative solutions for industrial water treatment, the utilization of alternative energy sources and the chemical industry. Outotec shares are listed on NASDAQ OMX Helsinki. www.outotec.com

Outotec® is a registered trademark. Copyright © 2015 Outotec Oyj. All rights reserved.

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