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A Steam Power Plant converts the chemical energy of the fossil fuels
(coal, oil, gas) or fissile fuels (Uranium, Thorium) into electrical energy.
Steam Power Plant basically works on Rankine cycle. Steam is produced
in the boiler by utilizing the heat of fuel combustion; thus steam is
expanded through the steam turbines. The Steam turbine drives the
generator which converts mechanical energy of the turbine into electrical
energy.
STEAM POWER PLANT
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Modern Steam Power Plant
Major Components of Steam Power Plant
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ID and FD Fan
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Feed Water And Steam Flow Circuit
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Cooling Water Circuit
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Closed System:
When enough quantity of water is not
available the same water will be used in the
condenser. The heated water from the
condenser is cooled by cooling tower or
spray pond and recirculated. Make up water
is added periodically to cover the water/
steam loss.
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Depends on
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Effect of Steam Temperature on Cost and Efficiency
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Factors affecting the Selection of Equipment
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Fuels and Coal handling Equipments means of coal Shipment
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Requirement of Good Coal Handling Plant
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Mechanical Handling vs Manual handling
1. Higher Reliability
2. Less Labour required
3. Economical for medium and Large capacity plants
4. Operation is Easy and Smooth
5. Can be easily started and economically adjusted
as per need
6. Minimized labour and hence easier management and
control of the plant
7. Reduced health hazards as less labour involved
8. Losses in transport – minimized.
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Mechanical Handling vs Manual handling
Disadvantages of Mechanical Handling:
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Coal Delivery Unloading Preparation
Transfer Out door Storage Covered
Storage In-plant Handling Weighing
and Measuring Furnace Firing
8. Weighing and
7. In-plant Handling Measuring 9.Furnace Firing
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Various Stages of
Coal handling
1. Coal Delivery
2. Unloading
3. Preparation
4. Transfer
5. Outdoor Storage
6. Covered Storage
7. Inplant Handling.
8. Weighing and
measuring
9. Furnace Firing
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Coal delivery
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The type of equipment to be used for unloading
the coal received at the power station depends
on how coal is received at the power station.
If coal delivered by trucks, there is no need of
unloading device as the trucks may dump the
coal to the outdoor storage.
Coal is easily handled if the lift trucks with
scoop are used.
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In case the coal is brought by railways
wagons, ships or boats, the unloading may be
done by car shakes, rotary car dumpers,
cranes, grab buckets and coal accelerators.
Rotary car dumpers although costly are quite
efficient for unloading closed wagons.
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Lift Truck with Scoop
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When the coal delivered is in the form of big
lumps and it is not of proper size, the
preparation (sizing) of coal can be achieved
by crushers, breakers, sizers, driers and
magnetic separators.
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Fuel/Coal Handling Equipment
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Bucket Conveyor/elevators move bulk
material vertically much like the conveyor
belt.
Buckets are attached to a rotating belt and fill
with the material at the bottom of the
elevator then move it to a designated point.
When the bucket reaches this point, it
discharges the contents, returns to the start
point, and begins the process again. Buckets
prevent spillage with their upright position
design.
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3. Screw Conveyor
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4. Grab Bucket Conveyor
Capacity
~ 50 tonnes/ h
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5. Flight Conveyor
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Lay out of a Fuel handling Equipment
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Outline of Coal Handling Equipment
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A Fuel is basically a source of heat. The usual method of
producing heat from fuel is by the process of
Combustion.
It is a chemical reaction between the Fuel and the
Oxidant.
The combustion efficiency depends on:
Hand firing:
• This is the simplest method of fuel firing. The
combustion efficiency is very low, when compared to
others.
• Due to lower combustion efficiency it cannot be
used in Modern power plants. 54
This is a simple method of firing coal into the furnace.
It requires no capital investment. It is used for smaller
plants.
Adjustments are to be made every time for the supply
of air when fresh coal is fed into furnace.
Hand fired grates: used to support the fuel bed and
admit air for combustion.
While burning coal the total area of air openings
varies from 30 to 50% of the total grate area.
The grate area required for an installation depends
upon various factors such as its heating surface, the
rating at which it is to be operated and the type of fuel
burnt by it.
The width of air openings varies from 3 to 12 mm.
The construction of the grate should be such that it is
kept uniformly cool by incoming air. It should allow
ash to pass freely.
Hand fired grates are made up of cast iron.
Stoker Firing
• A stoker is a power- operated fuel feeding
mechanism using a grate.
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Stokers
Overfeed Underfeed
Stoker Stoker
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Over feed stokers
• In the overfeed mechanism a forced draught fan slightly
pressurizes the atmosphere air before it enters under
the bottom of the grate.
• The fuel bed receives fresh coal on top surface
• The ignition zone lies between green coal and
incandescent coke.
• The air gets heated up as it follows through the grate
openings where as the grate gets cooled.
• This warm air gets additional heat energy by further
passing through a layer of hot ashes.
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O2+CO2+N2+
Flame Secondary
VM+CO+CO2
Green Coal
Incandescent coke
ASH CO+CO2+N2+
Grate
Primary Air
Different types of over feed stokers:
These type of stokers are used for large capacity
boiler installations where the coal is burnt
without pulverization.
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A chain grate stoker consists of an endless
chain which forms a support for the fuel bed.
The chain surface is made of a series of cast
iron links connected by pins.
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The chain travels over two sprocket wheels
located at the front and at the rear of the
furnace.
The front sprocket is connected to a variable
speed drive mechanism
Speed range 15 cm/ min to 50 cm/ min
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The chain travels over two sprocket wheels, one at the front and one at the rear of furnace. The
traveling chain receives coal at its front end through a hopper and carries it into the furnace.
The speed of grate (chain) can be adjusted to suit the firing condition.
The air required for combustion enters through the air inlets situated below the grate.
The stokers are suitable for low ratings because the fuel must be burnt before it reaches the rear of
the furnace.
ADVANTAGES:
1) Simple in construction
2) Low initial cost.
3) Self-cleaning stoker.
4) The rate of heat release can be controlled just by
controlling chain speed.
5) Rate of heat release is high per unit volume of furnace.
DISADVANTAGES:
1) cannot be used for high capacity boilers.
2) temperature of pre-heated air limited to 180 0 C
3) clinker troubles are very common.
4) loss of coal in the form of fine particles - carried away
with the ash.
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Spreader stoker mechanism involves throwing
(spreading) the coal uniformly on the grate.
The grate may be of stationary or moving type, with
air openings for admitting the air.
The selection of coal size is very important for a
spreader stoker
-- the coal size should be in between 6 cm to 36 cm.
The spreader stoker is mostly used for steam
capacities of 9.5 to 50 kg/sec. (34 to 180 tonnes/hr)
It can burn a wide variety of coals from high ranking
bituminous to lignite.
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Advantages:
1) A wide variety of coal can be burnt.
2) The clinkering problems can be reduced by spreading action.
3) High temperature preheated air can be used.
4) Volatile matter is removed by burning coal in suspension.
5) Good response to load fluctuation.
6) Low running cost.
Disadvantage:
Difficult to operate with varying sizes of coal
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1)This underfeed mechanism is best situated for
bituminous and semi bituminous coals.
2)In this underfeed mechanism the fuel is fed
from underneath the fire and moves upwards
gradually.
3)The air entering through the grate opening
comes in contact with raw fuel and mixes with
the volatile matter released from raw fuel and
enters into the combustion chamber.
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Principle of Underfeed Stokers
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Different types of under feed stokers.
1) single retort stoker
2)multi-retort stoker.
Single retort stoker
The single retort stoker consists of a trough
shaped retort to which the fuel (coal) is fed by a
reciprocating ram or screw conveyor.
The capacity of this stoker ranges from 100 to
2000 kg of coal burned per hour.
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The coal falling from the hopper is pushed forward
during the inward stroke of stoker ram. The distributing
rams (pushers) then slowly move the entire coal bed
down the length of stoker.
The slope of stroke helps in moving the fuel bed
downwards.
The primary air enters the fuel bed from main wind box
situated below the stoker. Partly burnt coal moves on to
the extension grate.
The air entering from the main wind box into the
extension grate wind box is regulated by an air damper.
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The number of retorts may vary from 2 to 20 with
coal burning capacity of 300 to 2000 kg/hr.
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1)High thermal efficiency when compared with
chain grate stoker.
2) The grate is self cleaning.
3)Part load efficiency is high with multiple retort
system.
4) high combustion rate.
5) wide variety of coals can be used.
6)best suitable for non-clinkering, high volatile
and low ash content coals.
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1)Initial cost is high.
2) Large building area is required.
3)Clinker troubles are usually
present.
4)Low grade fuels with high ash
content
cannot be burnt economically.
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• A pulverized coal-fired boiler is an industrial or utility
boiler that generates thermal energy by burning pulverized
coal (also known as powdered coal or coal dust since it is
as fine as face powder in cosmetic makeup) that is blown
into the firebox.
• The basic idea of a firing system using pulverised fuel is to
use the whole volume of the furnace for the combustion of
solid fuels.
• Coal is ground to the size of a fine grain, mixed with air and
burned in the flue gas flow. Biomass and other materials
can also be added to the mixture.
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• Coal contains mineral matter which is converted to ash
during combustion. The ash is removed as bottom ash
and fly ash.
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Pulverized coal power plants are broken down into three
categories; subcritical pulverized coal (SubCPC) plants,
supercritical pulverized coal (SCPC) plants, and ultra-
supercritical pulverized coal (USCPC) plants.
The primary difference between the three types of pulverized
coal boilers are the operating temperatures and pressures.
• Subcritical plants operate below the critical point of
water (647.096 K and 22.064 MPa).
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There are two requirements which are must for
Pulverised Coal to burn successfully in a furnace.
1)Presence of large quantities of Fine particles
of coal usually that would pass enough through
a 200-mesh to ensure Spontaneous Ignition
because of their large surface to volume ratio.
2)Presence of minimum quantity of Coarser
particles to ensure High Combustion Efficiency.
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ELEMENTS OF PULVERIZED COAL SYSTEM
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1)Any grade ofcoal can be used efficiently
because it is powdered before use.
2) Higher boiler efficiency due to complete
combustion.
3)Flexible method and can respond well for
sudden change in demand.
4) Fan power required is low.
5) Free from clinker problem.
6) Volume of the furnace required is less.
7) No major problem in ash handling.
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8)The system works successfully with or in
combination with gas and oil.
9)No moving parts in the furnace are subjected
to high temperatures.
10)Much smaller quantity of air is required as
compared to the stoker firing.
11)The external heating surfaces are free from
corrosion.
12)It is possible to use highly preheated
secondary air (350 deg. C) which helps in rapid
flame propagation.
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1)Additional investment for coal preparation
unit/ plant.
2) Extra power is needed for pulverising coal.
3)Maintenance cost is more which depends on
quality of coal.
4)Due to very high temperature, maintenance of
furnace walls is difficult.
5) More space is required.
6)Special equipment is required to start the
system.
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Coal is pulverized (powdered) to increase its surface area (and
therefore exposure) thus permitting rapid combustion.
The pulverized coal is obtained by grinding the raw coal in
pulverizing mills. Various types of pulverizing mills are:
Ball mill
Ball and race mill
Hammer mill
Bowl mill
Coal from bunker is fed by gravity to a dryer where hot air is admitted to dry
the coal.
Dry coal is then transferred to the pulverizing mill.
Pulverized coal then moves to a cyclone separator where transporting air is
separated from coal.
Primary air is mixed with coal at the feeder and supplied to the burner.
Secondary air is supplied separately to complete the combustion
1) Simple layout and easy operation.
2) It requires less space.
3)It is cheaper when compared with central
system.
4) Less maintenance.
5) Simple coal transportation system.
6)Direct control of combustion from the
pulveriser is possible.
7) Better control over fuel feed rate.
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1) Less flexible when compared to central system.
2)With the load factor in common practice, the
total capacity of all the mills must be higher than
for the control system.
3)Any fault in the coal preparation unit may stop
the entire steam generating system.
4)Excessive wear and tear of the fan blades as it
handles air and coal particles.
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1)More flexible because the quantity of fuel and
air can be controlled separately.
2) More reliable.
3) No problem of excessive wear of fan blades.
4) Less labour is required.
5)Low power consumption per tonne of coal
handled.
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1) High initial cost.
2) It requires large space area.
3) Possibility of fire and explosion hazards.
4) Driers are necessary.
5)Operation and maintenance costs are high
when compared to unit system of same
capacity.
6) More number of auxiliaries.
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Various types of burners are used
for combustion of pulverized coal.
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Contd.
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Various types of burners are used for
combustion of pulverized coal.
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Long Flame (U-Flame) Burner: In this burner, air and coal
mixture travels a considerable distance thus providing sufficient
time for complete combustion
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In this system, the coal and air will be
mixed due to cyclonic whirling action
The coal is crushed into tiny powder in
addition to pulverized coal
The ash is easily collected due to cyclonic
action
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Cyclone Burner: In this system, the cyclonic action whirls coal
and air against the wall of the furnace to facilitate thorough
mixing of coal and air.
Advantage of this burner is that it can also use crushed coal
in addition to pulverized coal thus providing an option.
When crushed coal is used, ash is collected in molten form for
easy disposal.
1)Costly pulverisers are not required. Instead,
simple coal crushing equipment can be used.
2)By using forced draught fan it can be operated
with small quantities of excess air.
3) It can burn low grades of coal effectively.
4) High temperatures are obtained.
5)Boiler fouling (sticking) problems can be
reduced as all the incombustibles are retained in
the cyclone burner.
6) Boiler efficiency is increased.
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Ash Disposal Equipment.
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Hydraulic System
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Ash Disposal Equipment contd.
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Below the boiler nozzles(top and sides), are fixed
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Pneumatic or Vacuum Extraction Ash Handling
System
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Ash handling Equipment-Desired Characteristics
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i. Enough capacity to cop e up with the volume of ash
being produced
ii. Able to handle large clinkers (stony residue),
boiler refuse, soot etc. with little personal attention of
the workmen.
iii. Able to handle hot and wet ash effectively and with
good speed.
iv. Possible to action of the ashes while minimize
corrosive or abrasive
v. economical in erection and operation.
vi. noiseless
vii. Should be possible to add additional units
Equipment commonly used for Ash Handling
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i. Bucket Elevator
ii. Bucket Conveyor
iii. Belt Conveyor
iv. Pneumatic Conveyor
v. Hydraulic Sluicing Equipment
vi. Trollies or Rail cars etc.
i. in the production of Cement
ii. Production of concrete (20% Fly Ash And
30% Bottom Ash)
iii. Treating acidic soils
iv. Extraction (Recovery) of metals such as
Al, Fe, Si, and Titanium from the ash
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Ash Disposal Equipment
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General layout of ash handling system
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Mechanical ash handling system
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Hydraulic ash handling System
• Low velocity
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High velocity
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Pneumatic ash handling system
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DUST COLLECTORS
Dust collectors are grouped into two types
1.Mechanical Dust Collectors
i) Wet type dust collectors
ii) Dry type dust collectors
Gravitational separators
Cyclone separators
2. Electrical Dust Collectors
i) Rod type
ii) Plate type
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Basic Principles of Mechanical Dust
Collectors
Enlarging the duct cross sectional area to slow down the gas gives
the heavier particles a chance to settle out.
When a gas makes a sharp change in flow direction, the heavier
particles tend to keep going in the original direction and so settle
out.
Impingement baffles have more effect on the solid particles than the
gas, helping them to settle.
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Mechanical Dust Collectors
i) Wet type dust collectors:
Wet types called scrubbers operate with water sprays to wash dust
from the air.
Large quantities of wash water are needed for central station gas
washing that this system is seldom is used.
It also produces a waste water that may require chemical
neutralization before it can be discharged into the central bodies of
water.
ii) Dry type dust collectors:
These are commonly used dust collectors.
a) Gravitational Separators: These collectors act by slowing down
gas flow so that particles remain in a chamber long enough to settle
in the bottom. They are not very suitable because of133large chamber
volume needed.
Cyclone (or) Centrifugal
separator
• The cyclone is a separating chamber
where in high-speed gas rotation is
generated for the purpose of centrifuging
the particles from the carrying gases.
• There is an outer downward flowing
vortex which turns into an inward flowing
vortex.
• Involute inlets and sufficient velocity head
pressures are used to produce the
vortices.
• The factors which affect the performance
are gas volume, particles loading, inlet
velocity, temperature, diameter- to- height
ratio of cyclone and dust characteristics.
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Advantages and Disadvantages of Cyclone Separator
ADVANTAGES:
Rugged in construction
Maintenance costs are relatively low
Efficiency increases with increase in load
Easy to remove bigger size particles
DISADVANTAGES:
Requires more power than other collectors
Incapable to remove dust and ash particles which
remain in suspension with still air
Less flexible
High pressure loss
Requires considerable head room and must be placed
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Electrical Dust Collector
The precipitator has two sets of electrodes, insulated
from each other, that maintain an electrostatic field
between them at high voltage
The field ionizes dust particles that pass through it,
attracting them to the electrode of opposite charge.
The high voltage system maintains the negative potential
of 30,000 to 60,000 volts with the collecting electrodes
grounded.
Accumulated dust falls of the electrode when it is rapped
mechanically
Wet type of unit removes dust by a water film flowing
down on the inner side of the collecting electrode.
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Layout of Dust Collection
System
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