Aerated Static Pile Composting - The Maryland Horse Council
Aerated Static Pile CompostingApplications and OpportunitiesI N T R O D U C T I ON A N D O V E R V I E WMARYLAND DEPARTMENT OF AGRICULTUREJANUARY 26, 2019PETER MOON, P.E. - O2COMPOST
Objective: To Convert Raw Feedstocks
Into High Quality Soil Amendments
Using the Aerated Static Pile MethodSonoma Valley Stables, Petaluma, CA
What isComposting?
This is Not Composting
This is Composting
This is Not Composting
This is Composting24 Horses on Saw Dust Bedding
This is Not Composting
This is Composting
One Definition of CompostingWA Solid Waste Handling Standards: WAC 173-350-100"Composting" means the biologicaldegradation and transformation oforganic solid waste under controlledconditions designed to promote aerobicdecomposition.”
One Definition of CompostingWA Solid Waste Handling Standards: WAC 173-350-100“Natural decay of organic solid wasteunder uncontrolled conditions is notcomposting.”
Front End Loader Turned Windrows
Tow Behind Windrow Turner
Oxygen Consumption with TimeAerobico2Anaerobic
Aerated Static Pile (ASP) CompostingHorse Manure w/ Shavings
ASP CompostingFirst Developed in the Early 1970’s – Beltsville MethodMaintains Aerobic Conditions Throughout the PileControls Pile Temperatures by Adjusting AirflowEliminates the Need to Turn the Compost PileSaves Time and Reduces the Cost of Labor and Fuel
Advantages of ASPComposting?WITH ASP COMPOSTING, WE: Construct the compost pile over a network of aeration pipes and Induce airflow into the pile using an electric blower / timer Do not turn the pile during the first 21 – 30 days (Active Phase) Adjust the airflow to manage pile temperatures and optimize thebiology of the composting process; and Operate the blower using either grid power or solar power
The Anatomy of an Aerated Static PileHorse Manure w/ Shavings
Isometric View - Aerated Static Pile11L’H’W’Rule of ThumbMax Pile Length 75 – 80-feet
Plan ViewLength 75 – 80 FeetHeight 12 FeetL’W’
Cross Section View of an ASP1H’6-12’1MixW’Rule of Thumb:Max Pile Length 75 – 80-feet
Section View of an ASPPipes on Grade Thin Wall – Pilot Test Thick Wall HDPEH’MixW’Rule of Thumb:Max Pile Length 75 – 80-feet
Section View of an ASPBelow Grade Trenches Aeration DrainageH’MixW’Rule of Thumb:Max Pile Length 75 – 80-feet
Section View of an ASPPipes on GradeAeration Plenum Layer Wood Chips Screen-OversH’MixW’Rule of Thumb:Max Pile Length 75 – 80-feet
Section View of an ASPPipes on GradeAeration Plenum LayerInitial Mix of Materials C:N RatioH’Mix Bulk Density Moisture ContentW’Rule of Thumb:Max Pile Length 75 – 80-feet
Section View of an ASPPipes on GradeAeration Plenum LayerInitial Mix of MaterialsBiofilter Cover LayerH’MixW’ Unscreened CompostRule of Thumb:Max Pile Length 75 – 80-feet
Biofilter Cover LayerUnscreened Compost Cover (1-foot)MixW’H’ Insulating Layer (PFRP) Biofiltration Layer Nutrient Retention Vector Barrier Moisture Retention Improve AestheticsRule of Thumb:Max Pile Length 75 – 80-feet
Partially Constructed ASPASP Hands-on Workshop
Constructing an ASP in 2 Minutes or Less
Section View of an Extended ASPUnscreened Compost CoverMixH’Cell 1Cell 2Screen Overs PlenumW’Cell 3Cell 4
Extended ASP CompostingUpper Valley Disposal Service, Rutherford, CA
The Importance of AerationBY INDUCING AIRFLOW INTO THE COMPOST PILE WE ARE ABLE TO: Maintain aerobic conditions without turning the pile Optimize the biology of the composting process Manage pile temperatures Reduce offensive odors and neighbor complaints Expedite the rate of composting Produce a high quality compost product in less time
Top-Down Aerated Bay System
Liberty Bell Farm, SnohomishCompleted Aeration System
Cross Section of an Aerated Bin
Cross Section of an Aerated BinRaw Mix 30-days to fillMoisture 60 – 65%
Cross Section of an Aerated BinCompost Cover Thermal Blanket Odor Control Fly Control Retains Moisture
Cross Section of an Aerated BinTypical Aeration Cycle: 2-min ON & 30-min OFFNoTurning!O2
Cross Section of an Aerated BaySteamHighest Heat131oF131oF
Cleaning Out Wet Bedding
Removing Solid Manure
Moisture Conditioning the Mix
Dumping Cart into Compost System
Adding Final Cover Layer
Adding the Final Touch
Monitoring Compost Temperatures
Cross Section of a 3-Bay System - Stage 1Start AirflowNo AirflowEmptyBin #1Bin #2Bin #3Active PhaseFillingEmpty
Cross Section of a 3-Bay System - Stage 225 – 40%Volume Loss 100 - 110oF 140 - 165oF10% Airflow90% AirflowNo AirflowBin #1Bin #2Bin #3Curing PhaseActive PhaseFilling
Cross Section of a 3-Bay System - Stage 3Empty10% Airflow90% AirflowBin #1Bin #2Bin #3Ready for Batch #4Curing PhaseActive Phase
The Evolution ofO2Compost SystemsSince 1998
Chicken Mortality CompostingDraper Valley Farms, Mt. Vernon, WA
Chicken Mortality CompostingDraper Valley Farms, Mt. Vernon, WA
Chicken Mortality CompostingDraper Valley Farms, Mt. Vernon, WA
Prototype Compost SystemO2Compost “Research Laboratory”
On-Grade Aerated Compost SystemsSonoma Valley Worm Farm, CA
On-Grade Aerated Compost SystemsGreenville, NC
On-Grade Aerated Compost SystemsCamden, NCNewly Constructed in NC - 2009
Top-Down Compost SystemsHorse Manure / Wood Pellet Bedding
Adding Raw Manure from Above
Removing Compost from Below
Top Down 3-Bin Compost StructureNickerson Farm – Sterling, MA
Aerated Static Pile CompostingPART 2VIRTUAL TOUR OFASP COMPOST FACILITIES
O2Compost Micro-Bin SystemPlywood & 2 x 6 Tongue & Groove Bins
Top Down, Sliding LidCompost SystemLow Profile, Aesthetically Pleasing
Aerated Static Bin CompostingEdwards Equestrian Center, MT
Aerated Static Bin CompostingMohican Farm, Cooperstown, NYQuaker Smith Point, VT
Aerated Bay CompostingSilver Oaks Stable, Long Island, NY
Aerated Block Bay SystemThacher School – Ojai, CA
Free-Standing Aerated Static PileDetweiler Homestead Farm, PA
Aerated Static Pile CompostingMicro-Green Farm, NJ
Extended Aerated Static PileTwo Particular Acres – Royersford, PA
Simple On-Grade Pipe SystemBailey Compost, WA
Large Aerated Bay CompostingLenz Enterprises – Stanwood, WA
The Benefits of ASPCompostingWITH ASP COMPOSTING, WE: Reduce the footprint of the Active compost pad Increase site capacity as well as the throughput of a given facility Reduce the cost of processing (less equipment, labor and fuel) Resolve off-site odor impacts and neighbor complaints Process more challenging feedstocks Improve product quality and increase the selling price
Pop QuizThe three layers within an Aerated Static Pile Include:The Plenum Layer – Why is this important?To help distribute airflow uniformly across the base of the pileThe Mix Layer – What are the Key ParametersNutrient Balance (Carbon to Nitrogen Ratio)Bulk Density as an indirect measure of PorosityMoisture ContentThe Biofilter Layer – What are the two key reasonsInsulate the mix layer pile temperatures over 131oF for 3 daysManage odors and off-site impacts to neighbors
Aerated Static Pile CompostingPART 3COMPOSTING IS A BIOLOGICPROCESS
The Secret to Composting is Oxygen!
Oxygen Consumption with TimeAerobico2Anaerobic
The Composting ProcessWaterHeatCO2RawOrganicMatterMinerals1) MixWaterCompostPileMicro OrganismsRaw Materials3) ished Compost2) Oxygen
AerationAllows the Operator to:Maintain Aerobic ConditionsMitigate Impacts from Objectionable OdorsManage Pile TemperaturesReduce the Loss of NutrientsFacilitate the Rate of Composting & CuringProduce Superior Compost Products
Compost Mix – The Key to Success4 Critical Parameters1.Carbon to Nitrogen Ratio (C:N 30:1)2.Porosity: Volume of Void SpaceBulk Density: 550 – 950 pounds per cubic yardFree Airspace: 35 to 60%oo3.Moisture Content (60 – 65%)4.pHoBacterial decomposers prefer pH 6.0 to 7.5.oFungal decomposers prefer pH 5.5 to 8.0.oIdeal range is 5.8 to 7.2
Requirements for Aerobic CompostingParameterC:N RatioReasonable Range20:1 to 40:1ASP Preferred Range25:1 to 30:1Moisture40% to 65%60% to 65%Bulk DensityFree Air Space650 to 1,250 pcy35% to 60%950 pcy (max)35% to 50%pH5.5 to 8.56.5 to 8.0Particle SizeO2 Concentration1/16” to 3” 5% 50% 1/8” to 2” (max) 10%Temperature131o to 170oF131o to 150oF
The Compost Life-CycleTemperature oF180160155oF140131oF120A MesophilicB ThermophilicC CuringD MaturationPFRP110oF100806040Active Composting PhaseABCuring and Maturation PhaseCTimeD
Actual Temperature Data Curve140135Temperature, 8Feb
Mid-Term ExamAfter turning a compost pile, or when the blower foran Aerated Static Pile turns off, how quickly does theoxygen deplete in the core of the pile?What percentage of O2 do we want to maintain in anaerobic system?Active Composting is primarily a drivenprocess whereas Curing is primarily adriven process.
Mid-Term ExamTrue or False: Curing starts at an exact point in timePFRP means a Process to .What are the criteria for PFRP with ASPComposting?Our objective in meeting PFRP conditions are to“destroy” . At these temperatures wealso effectively eliminate and .
Bonus PointsWhat is the one correct answer to all compostingquestions?It Depends!
Aerated Static Pile CompostingPART 4COMPOSTING AS AMANUFACTURING PROCESS
Composting Process Flow Chart
Mass Balance AnalysisTilz Soil & CompostIn-Bound Green Waste per YearProcess Mass Balance7,000tons / yrAverage ConditionMonthly Tonnage583Shredded Bulk Density650 pounds / cubic yardMonthly VolumeVolume Loss w/ Active CompostingVolume After Active CompostingVolume Loss w/ CuringVolume After Curing1,795tons / mo.cy / avg. mo.25%1,346Peaking ValuePeak Condition729tons / mo.650 pounds / cubic yard2,244cy / peak mo.25%cy / avg. mo.10%1,212125%1,683cy / avg. mo.10%cy / avg. mo.1,514cy / peak mo.Screened Fines Proportion60%Screened Product Volume727Screen "Overs" Proportion45%Screened "Overs" Volume545cy / avg. mo.681cy / peak mo.Curing Time1.5months1.5monthsCuring Storage VolumeScreened Product Storage TimeScreened Product Storage VolumeScreen Overs Storage TimeScreen Overs Storage Volume2,01932,18131,63660%cy / avg. mo.909cy / peak ymonthscy
Continuous Flow
Materials HandlingWhen the method of mixing and processing is successfulat meeting the biological requirements for composting: The primary focus of composting then becomesmaterials handling. Composting is a manufacturing process, and The objective should be to produce a high qualityproduct.
AdaptabilityYour Method of Operating Will Evolve Over TimeRecommendations:Start small and grow in planned increments.Define your key objectives & set goals.Always strive to improve product quality.
AdaptabilityYour Method of Operating Will Evolve Over TimeAlways work to reduce materials handling;Identify and manage constraints in your system;Respond to regulatory changes;Be a good neighbor; andKeep it Simple Stupid (KISS).
Summary – Keys to SuccessManage the compost facility based on a continuous yetvariable flow of materials (i.e., Flow Diagram);Handle raw feedstocks promptly;Pay particular attention to: 1) aeration; and 2) theamount of moisture in the system;Do not lose sight of the big picture; manage the site bypracticing good housekeeping techniques; andAlways strive to improve product quality!
Aerated Static Pile CompostingPART 5CONDUCTING ANASP PILOT PROJECT
The Four Stages of LearningUnconscious IncompetenceDon’t know what you don’t knowConscious CompetenceKnow what you knowConscious IncompetenceKnow what you don’t knowUnconscious CompetenceDon’t know what you know
Learning by DoingBridging the Gap BetweenKnowledge and Understanding
Small Volume Pilot ProjectsQuick and Inexpensive toConstruct & Start-upPrototype Compost MixC:N RatioBulk DensityMoisture ContentConfirm Suitability BeforeSetting up a Larger PileGet Stakeholder Buy-InO2Compost Micro-Bin System
Large Volume Pilot ProjectsProvide Operator TrainingResolve Logistical ConstraintsTest a Variety of MixesEstablish Standard OperatingProceduresReveal Permit RequirementsEstablish RegulatoryO2Compost Aerated Bay SystemConfidence.
LogisticalConstraints FeedstockSources Transportation AerationSystem Equipment Operators Power/Water PermitsSalt Lake City Pilot Project
StakeholderBuy-In Partners Investors Employees Regulators Neighbors Customers End-UsersFish Waste Compost Demonstration Project
Aerated Static Pile CompostingPART 6INCREASING SITE CAPACITY BYREDUCING OPERATINGFOOTPRINT
WindrowTurnersSelf Propelled Straddle Type 16-feet wide by 7-feet high
WindrowTurnersPTO Powered - Tow Beside 16-feet wide by 7-feet high
Example Turned Windrow Compost FacilitiesCompost Facility in New YorkYard Waste & LeavesCompost Facility in CaliforniaYard Waste & Food Waste
Turned Windrow Compost FacilityCompost Facility in TexasBiosolids with Shredded Wood15 Windrows 7,500 cyProblem: No Room to Expand
Turned Windrows 2.4 acres
Site Dimensions and Turned Windrow CapacitySite Dimensions: 350-feet x 300-feet: 2.4 AcresWindrows: 16-feet wide, 6-feet high, 300-feet longWindrow Volume: 500 cubic yards / windrow15 Windrows: Total Volume 7,500 cubic yard
Turned Windrows 2.4 acres
EASP Batch Flow-Through CompostingBailey Compost, Snohomish, Washington
Section View of an Extended ASPUnscreened Compost CoverMixH’Cell 1Cell 2Screen Overs PlenumW’Cell 3Cell 4
Extended Aerated Static Piles
Site Dimensions and EASP CapacitySite Dimensions: 350-feet x 300-feet: 2.4 AcresEASP: 80-feet wide, 135-feet long, 10-feet highEASP Volume: 3,250 cubic yards / EASP7 EASP’s: Total Volume 22,750 cubic yardsIncreased Capacity: 22,750 cy / 7,500 cy 3xTow Beside Windrow Turners: 6x – 8x
Extended Aerated Static Piles
Extended ASP CompostingBailey Compost, Snohomish, Washington
Continuous Flow “Wedge” MethodEnvirofert Compost, Auckland, New Zealand
Blowers & Manifold SystemAuckland, New Zealand
Advancing / Receding FacesAuckland, New Zealand
Advancing / Receding Faces( )Auckland, New Zealand(-)
Aerated Static Pile CompostingPART 7RESOLVING ODOR IMPACTS&NEIGHBOR COMPLAINTS
The ChallengeOffensive Odors are the single most commonreason for compost facility closure.Impacted neighbors become upset, organizedand relentless in their goal to shut downoffending compost facilities.Despite this, they are not the enemy!
TurningWindrowsCore Gases Releasedfrom an anaerobiccompost windrow in aneffort to reestablishaerobic conditionswithin the pile.Odors can beparticularly strong andoffensive when thefeedstocks consist ofhigh nitrogen manure,grass clippings and foodwaste.Photo: BioCycle Magazine
ExtendedAerated StaticPileNo Pile Turningduring the first 30days of ActiveCompostingBlowers Operated byOn/Off Cycle TimersEasy to MaintainAerobic ConditionsThroughout the PilePhoto: Ned Foley TwoParticular Acres Compost,Royersford, PA
Oxygen Consumption with TimeAerobico2Anaerobic
Most Odors are By-Products of Anaerobic RespirationRotten Eggs - dimethyl sulfide, hydrogen sulfide.Rancid Fats, Oils & Grease - butyric acid.Dead Animals - putrescine, cadaverineFishy – trimethyl aminePine - terpene. volatile organic compounds Ammonia – not O2conditions function (pH)
How Do Anaerobic Compounds Form?Under conditions that restrict the entry of oxygen intofeedstocks or compost piles.High moisture contentInadequate porosity (high bulk density)Rapidly degrading substratesExcessive pile size
How do you remediateanaerobic metabolism?ADD OXYGENAND MAKE SURE THE MIX WILL SUPPORTAEROBIC MICROBES!
Section View of an ASPUnscreened Compost Cover (1-foot)MixW’H’ Insulating Layer (PFRP) Biofiltration Layer Nutrient Retention Vector Barrier Moisture Retention Improve AestheticsRule of Thumb:Max Pile Length 75 – 80-feet
VOC Emission Reduction StudyTulare, CA 2012
OdorEvaluationGathered RepresentativeSamples from the Surfaceof Compost PilesEvaluated OdorCharacter and Strengthby Off-Site Odor PanelEvaluated ConstituentGasesMeasured VOC and GHGEmissions.C.E. Schmidt Environmental Consultants
The Benefits of ASP Composting with aBiofilter Cover LayerPollutantReductionVolatile Organic Compounds – VOC’s98.8 %Ammonia – NH383.2 %Carbon Dioxide - CO271.9 %Methane - CH413.0 %Nitrous Oxide - N2O88.8%Table ES-1: Results in emissions testing in pounds of pollutant per ton of feedstock over the22-day active composting period
Steps to Minimize Offensive Odors1.Receive and Process Odorous Wastes Promptly2. Provide Adequate Carbon-Rich Bulking Material3. Establish a Bulk Density of 650 – 950 pcy4. Place on an Aeration System ASAP5. Cover with a Biofilter Layer (unscreened compost)6. Maintain Aerobic Conditions for the first 30-days
People “Smell with Their Eyes” Good Housekeeping Clean-up Receiving Areas Temporary Covers on top ofRaw Feedstocks Overnight Clean Ditches and Puddles Aerate Stormwater & LeachatePonds Correlate MeteorologicalConditions and On-SiteActivities with ComplaintsLenz Enterprises - Stanwood, WA
Aerated Static Pile CompostingPART 8REDUCING OPERATINGCOSTS
Extended Aerated Static Piles
Turned Windrows 2.4 acres
Site Dimensions and EASP CapacitySite Dimensions: 350-feet x 300-feet: 2.4 AcresWindrow Volume: 7,500 cubic yards7 EASP’s: Total Volume 22,750 cubic yardsIncreased Capacity: 22,750 cy / 7,500 cy 3xTow Beside Windrow Turners: 6x – 8xIncreased Cycle Time: 1 ½ - 2x cubic yards / year
Composting Flow Chart
Composting Flow Chart
Process ComparisonTurned WindrowsAerated Static PilesWindrow ConstructionPile ConstructionWindrow Turning 8-16xNo Pile TurningTime on Pad: 6 – 8 wksTime on Pad: 4 – 6 wksPile DeconstructionPile DeconstructionMove to CuringMove to Curing
Process ComparisonTurned WindrowsAerated Static PilesWindrow ConstructionPile ConstructionWindrow Turning 8-16xNo Pile TurningTime on Pad: 6 – 8 wksTime on Pad: 4 – 6 wksPile DeconstructionPile DeconstructionMove to CuringMove to Curing
WindrowTurnersSelf Propelled Straddle TypeWindrow Turner16-feet wide by 7-feet high
Turned Windrows – 22,750 Cubic YardsInvestment: 600,000 - 850,000Life Expectancy4 – 6 yearsLabor:80 hrs/mo.Fuel Cost: YY / mo.Routine Maintenance: ZZ / mo.Major Repairs: 10,000 - 20,000/yrInsurance:Strongly Recommended
Aerated Static Piles – 22,750 Cubic YardsInvestment: 25,000 - 50,000Life Expectancy20 years (plus)Labor / Site Inspections:2 hrs/wk or 8 hrs/mo.Power Installation Cost: 15,000 - 30,000Power Operating Cost: 100 - 250 / monthMaintenance & RepairsIncidentalInsurance:None Recommended
How Much Will My CompostSystem Cost to Build?There are Three Cost Components: O2Compost Training Program Construction Materials Construction Equipment and Labor
Average System CostsO2Compost SystemStyleO2CConstructioTraining MaterialsnTotal CostMicro-BinPortable 675 3250 1,000Macro-BinFixed 1,675 500 250 2,425Portable 2,475 2500 2,725Cornerstone 3-BayOn-Grade 2,475 2,5250 5,000Cornerstone 3-BayTop-Down 2,475 2,5000 4,950Sterling 3-BayOn-Grade 3,975 3,525 2,500 10,000Sterling 3-BayTop-Down 3,975 3,525 4,00011,500ParagonOn-Grade 3,000 5,250 2,500 10,750Cornerstone ASP
How Much Will My CompostSystem Cost to Operate?There are Four Cost Components:: Time to Prepare the Mix and Fill the BinTime to Monitor the Composting ProcessTime and Equipment to Remove the CompostElectrical Power
What About Getting a Grant to HelpPay for My Compost System? Paper Work, Paper Work, Paper WorkThis Process Can Take 12 to 18 monthsMore Stringent Construction StandardsCost Share of 1 : 1 After ConstructionOften it’s “Hurry-up and Wait”Open Invitation to Visitors
Return on Your InvestmentReduce ExpensesCreate Benefits Hard Costs Soft Costs Environmental Costs Intangible Costs Product Sales & Profits Improve Horses’ Health Improved Aesthetics Sustainable Agriculture
Hard CostsEliminate Disposal Expense
Soft Costs Owner’s Time and Effort Inefficient Use of Labor Excessive Bedding Fuel Costs Equipment Maintenance & Repairs Veterinarian Bills
Improving Horses’ HealthLush Pasture Grass - Parasites and Weeds?
When to Call Your Vet? Soft Costsowners’ time,fuel and equipment,horses’ health,Ascarid Impaction of SI
Environmental Costs
Protecting Aquatic LifeThe Chesapeake Bay watershed is64,000 square miles.It has 11,600 miles of tidal shoreline,including tidal wetlands and islands.The watershed encompasses parts ofsix states.Approximately 17 million people live inthe watershed.About 10 million people live along itsshores or near them.
Chesapeake Bay Watershed
Protecting Aquatic LifeAmmonia in Small Concentrations is Toxic to Salmonoids
Protecting Aquatic LifeHigh BOD and Nutrients in Runoff
Intangible CostsHuman HealthNeighbor ComplaintsRegulatory CompliancePoor Aesthetics & Lost BusinessDeferred MaintenanceFrustration and Sleepless Nights
Protecting Human HealthNitrates in the Ground Water
Benefits of Using Composto Convert Nutrients to plant available formso Increase soil organic contento Decrease soil compactiono Improve pasture grass, reduce weedso Increase infiltration and moisture retention in soilo Decrease soil erosion
Soil HorizonsTopsoil isOrganic Soila ComplexMineral SoilLivingOrganismParentMaterial
Soil is a Complex Living Organism
Q&AOklahomaNew JerseyMassachusettsWashingtonMaryland
Aerated Static Pile CompostingApplications and OpportunitiesTHANK YOUPETER MOON - O2COMPOST
Horse Manure w/ Shavings Aerated Static Pile (ASP) Composting. yFirst Developed in the Early 1970's -Beltsville Method yMaintains Aerobic Conditions Throughout the Pile yControls Pile Temperatures by Adjusting Airflow yEliminates the Need to Turn the Compost Pile . Fly Control
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e-PTFE expanded (Polytetrafluoroethylene) (and Polyester) Aerated Windrow Cover Materials Polypropylene (“fleece”) Aerated Windrow Cover Materials Polypropylene (woven) and Polyethylene (spun) . Aerated Windrow Cover Materials Biofilter-cover: Porous organic material Example: finish
Overview of Composting Methods and Operations Photo source: Bruce Fulford (I think) Why n-FarmO Composting? Long composting history on farms Examples from the early 1970's . On-Farm Composting Fini Bob Rynk SUNY, Cobleskill March 31, 2010. Title: Recycling Food Residuals via On-Farm Composting Author: US EPA Subject:
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