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4178 Ind. Eng. Chem. Res.

2005, 44, 4178-4185

Electrodissolution of Aluminum Electrodes in Electrocoagulation


Processes

P. Cañizares, M. Carmona, J. Lobato, F. Martı́nez, and M. A. Rodrigo*

Department of Chemical Engineering, Facultad de Ciencias Quı́micas, Universidad de Castilla La Mancha,


Campus Universitario s/n, 13071 Ciudad Real, Spain

The electrodissolution of aluminum electrodes in aqueous solutions containing sulfate or chloride


ions is studied in this work. The results obtained are important in order to obtain a better
understanding of the electrocoagulation process, as the electrodissolution of the anode surface
is its first step. It has been determined that both chemical and electrochemical dissolution play
an important role in the aluminum generation. The chemical dissolution of aluminum is strongly
influenced by the pH. Alkaline pHs increase the dissolution rate by orders of magnitude. Within
the experimental conditions used, the supporting media does not seem to influence greatly the
chemical dissolution process. The electrochemical dissolution process depends mainly on the
specific electrical charge passed. Salinity does not significantly affect the electrodissolution rate.
Good fittings between experimental and modeled data are obtained by modeling the system
with a simple model based on two assumptions: a highly segregated flow pattern and the
calculation of aluminium species and pH from a pseudoequilibrium approach.

Introduction
During the last few decades, electrochemical waste-
water treatment technologies have undergone rapid
development. One of these technologies is the electro-
chemically assisted coagulation that can compete with
the conventional chemical coagulation process in the
treatment of wastes polluted with colloids or macromol-
ecules or in the treatment of emulsions.1-8
Electrochemically assisted coagulation was seen as a
promising technology at the turn of the nineteenth
century, although it has received very little scientific
attention. In the following decades, plants were com-
missioned in the United States to treat municipal
wastewater. However, all such plants were abandoned
due to apparent higher operating costs and some
expectations of high initial capital costs as compared Figure 1. Main stages involved in the electrochemically assisted
to the case of chemical dosing. Recently, some works coagulation.
focused on the study of this technology have reported
promising results, and several firms have started to is often called electroflocculation. Finally, the pollutants
commercialize plants for treating actual wastes. Nev- are removed by sedimentation, filtration, or flotation
ertheless, to make this technology competitive with the from the waste. The bubbles formed in the oxygen and
conventional chemical coagulation process, more effort mainly in the hydrogen evolution can help to increase
has to be done in the next years, and a better under- the efficiency of the later process (electroflotation).11-16
standing of the processes involved must be achieved. Most works in the literature consider that the coagulant
The main stages involved in the electrochemically is obtained mainly by the electrodissolution of the anode
assisted coagulation are shown schematically in Figure surface, but recently, some authors17 have proposed
1.9-10 An electrochemical cell is used to provide alumi- that, to justify the electrocoagulation results, the chemi-
num or iron to the waste. These coagulant reagents cal dissolution of the electrodes should also be consid-
desestabilize the colloidal pollutants (or break the ered in this representation of the electrocoagulation
emulsion), similar to the case of a conventional coagula- process.
tion process. The turbulence generated by the oxygen The aim of this work is to study the electrodissolution
and the hydrogen evolution generates a soft mix that of the aluminum into wastes. The characterization of
helps the desestabilized colloids to flocculate (to link this first step is important in order to have a complete
together and to generate bigger particles). This process understanding of the electrochemical coagulation pro-
cess. To do this, the chemical dissolution of the alumi-
* To whom correspondence should be addressed. Tel.: num sheets and the electrochemical dissolution has been
+34 902 20 41 00. Fax: +34 926 29 53 18. E-mail: - studied and a model that considers both chemical and
Manuel.Rodrigo@uclm.es. electrochemical processes is proposed.
10.1021/ie048858a CCC: $30.25 © 2005 American Chemical Society
Published on Web 05/13/2005
Ind. Eng. Chem. Res., Vol. 44, No. 12, 2005 4179

Figure 2. Layout of the bench-scale plant, including detail of the


electrochemical section. Figure 3. Aluminum dissolved and pH variation during batch
chemical dissolution experiments carried out under nonalkaline
conditions: [ 2450 mg dm-3 NaCl, pH 3; 0 3000 mg dm-3
Experimental Section Na2SO4, pH 3; 2 2450 mg dm-3 NaCl, pH 7; O 3000 mg dm-3
Na2SO4, pH 7.
Experimental Devices. The electrochemical dis-
solution experiments have been carried out in a con- electrolyte, aqueous solutions with chloride or sulfate
tinuous bench-scale plant, with a single-compartment ions were tested. Prior to each experiment, the elec-
electrochemical flow cell (Figure 2). Aluminum elec- trodes were treated with a solution of 1.30 M HCl in
trodes (HE 18) were used as the anode and cathode. order to reject any effect due to the different prehistory
Both electrodes were square in shape (100 mm sides) of the electrodes.
with a geometric area of 100 cm2 each and with an Chemical dissolution experiments were carried out in
electrode gap of 9 mm. The electrical current was a batch operation using stirred beakers. These beakers
applied using a DC Power Supply, FA-376 Promax. The were initially filled with the solution of chloride (or
current flowing through the cell was measured with a sulfate), and a piece of aluminum was placed inside.
Keithley 2000 Digital Multimeter. The electrolyte was Samples were taken from the beakers, and the pH and
stored in a 5000 mL glass tank stirred by an overhead the aluminum were measured according to the methods
stainless steel rod stirrer, Heidolph RZR 2041, and previously described. The aluminum dissolution rates
thermostatized by means of a water bath to maintain were calculated after fitting the experimental data
the temperature at the desired set point, and circulated obtained in these essays to the mass balance equations
through the electrolytic cell by a peristaltic pump. of this batch reactor. The initial and the final weights
Chemical dissolution experiments were carried out in of the aluminum piece were also used to confirm the
stirred batch reactors. To do this, a multistirrer device, results.
Isco, was used.
Experimental Procedure. Electrochemical dissolu- Results and Discussion
tion experiments were carried out in the continuous-
operation bench-scale plant, under galvanostatic con- Chemical Dissolution of Aluminum. Figures 3 and
ditions. The electrolyte was pumped into the cell and 4 show, for four different pHs, the aluminum dissolved
collected in a tank. Samples were taken at the outlet of versus time in a batch reaction system when a sheet of
the cell, and pH was measured using an inoLab WTW 4 cm2 area (and 0.8 mm thickness) is placed into a
pH meter. To determine the total aluminum concentra- solution that contains sodium chloride or sodium sulfate.
tion, samples were diluted 50:50 v/v with 4 N HNO3, These figures also show the pH variation with time in
and after that, they were measured using a sequential each experiment.
inductively coupled plasma spectrometer, Varian Lib- It can be observed that, in all cases, a chemical
erty, according to an standard method18 (plasma emis- dissolution of the aluminum is obtained, with a linear
sion spectroscopy). Preparative experiments were car- trend for all the experiments except for that correspond-
ried out to determine the amount of passed solution ing to pH 13, in which the concentration of aluminum
required to reach the steady state. In every experiment, reached a final value due to the complete dissolution of
this final state was tested. To determine the influence the aluminum sheet. The pH decreases in every case,
of the passed electric current charge (I/Q), the flow rate although the change is more significative for a neutral
(Q) was maintained constant at 19.8 dm3 h-1 and the pH. The supporting media seems not to have an
employed current density was changed. The range of important effect on the dissolution results.
the passed electrical charge studied was 0.0007- Figure 5 shows the aluminum dissolution rates as a
0.0138 A h dm-3. To determine the influence of the pH, function of the pH. It can be observed that there is the
the feeding solution pH was changed in the range 1-13. presence of a minimum at a close to neutral pH and
To determine the influence of the current density, the that the dissolution rate is several orders of magnitude
current density and the flow rate were changed simul- higher at alkaline pHs. During the alkaline pH experi-
taneously in order to obtain the same amount of passed ments, hydrogen bubbles evolving from the sheet sur-
current charge. To test the influence of the supporting face were clearly observed.
4180 Ind. Eng. Chem. Res., Vol. 44, No. 12, 2005

Figure 4. Aluminum dissolved and pH variation during batch


chemical dissolution experiments carried out under alkaline
conditions: [ 2450 mg dm-3 NaCl, pH 12; 0 2450 mg dm-3 Figure 6. Concentration of aluminum, pH, and voltage profiles
Na2SO4, pH 12; 2 2450 mg dm-3 NaCl, pH 13; O 2450 mg dm-3 with time (dynamic response) generated in typical aluminum
Na2SO4, pH 13. electrodissolution experiments: current density, 0.5 mA cm-2;
temperature, 25 °C; flowrate, 19.8 dm3 h-1; pH, 6. Supporting
media: [ 2450 mg dm-3 NaCl; 0 3000 mg dm-3 Na2SO4.

Figure 7. Variation of the steady-state aluminum concentration


electrogenerated in the electrochemical processes with the electri-
Figure 5. Aluminum dissolution rates as a function of the pH. cal charge passed: T, 25 °C; pH, 6.0; flowrate, 19.8 dm3 h-1.
Supporting media: [ 2450 mg dm-3 NaCl; 0 3000 mg dm-3 Supporting media: [ 2450 mg dm-3 NaCl, 0 3000 mg dm-3
Na2SO4. Na2SO4. s Values predicted using Faraday’s Law.

Electrodissolution of the Aluminum Sheets. Fig-


ure 6 shows the aluminum, pH, and voltage profiles compared with the expected values if the process were
versus time (dynamic response) generated in typical purely electrochemical.
aluminum electrodissolution experiments (current den- As can be seen, the electrodissolved aluminum in-
sity ) 0.5 mA cm-2, temperature ) 25 °C, flow rate ) creases linearly with the electrical charge and the
19.8 dm3 h-1, and pH ) 6.0) carried out in a continuous experimental values are greater than the values calcu-
flow cell. lated if the process is purely electrochemical. In this
It can be observed that the concentration of aluminum figure, it can also be observed that the supporting media
increases with time up to a steady-state value. Likewise, does not seem to play an important role in the dissolu-
it can be observed that the bulk pH increases and the tion process.
cell voltage decreases and that both parameters also find Figure 8 shows the influence of pH in the steady-state
a steady-state value. concentration of aluminum. This figure also shows the
The steady-state value for the concentration of alu- theoretical value of the aluminum concentration if the
minum is greater than the expected value if the process process was uniquely electrochemical. It can be seen
is purely electrochemical. Thus, for the conditions used that the experimental values are greater than the
in the experiments shown in Figure 6, only 0.95 mg theoretical ones and that the differences increase in
dm-3 of electrodissolved aluminum was expected. The highly alkaline media. The discontinuous line corre-
pH increase can be justified by the hydroxyl ion genera- sponds to the amount of aluminum chemically dissolved
tion on the cathode as a consequence of the hydrogen at the pH of the bulk solution in the cell. It can be
evolution process. The cell voltage decrease can be observed that, only at pH 12, this line fits with the
justified by the increase in the ionic conductivity of the experimental points.
treated solution. Figure 9 shows the influence of the salinity and that
Figure 7 shows the variation of the steady-state of the current density for the same passed electrical
aluminum concentration electrogenerated in the elec- charge. It can be observed that, inside the conductivity
trochemical processes with the passed electrical charge, range used, the electrodissolved aluminum concentra-
Ind. Eng. Chem. Res., Vol. 44, No. 12, 2005 4181

Figure 8. Influence of pH on the steady-state concentration of


aluminum generated in the electrochemical processes: s Fara-
day’s Law; - - - aluminum chemically dissolved at the pH of the
bulk solution in the cell. T, 25 °C; j, 0.5 mA cm-2; flowrate,
19.8 dm3 h-1. Supporting media: [ 2450 mg dm-3 NaCl;
0 3000 mg dm-3 Na2SO4.

Figure 10. Main stages involved in the electrochemically assisted


coagulation process according to the results obtained in this work.

the cathode, where the pH can become strongly alkaline.


This can justify the important contribution of the
chemical dissolution to the total dissolution rate (Figure
10). To confirm this role of the chemical dissolution, a
model which considers both chemical and electrochemi-
cal processes is proposed in the next section and applied
successfully to the description of the process.
Model of the Electrodissolution Process. From
the experimental results described in the former sec-
tions, it can be concluded that, to model the electro-
dissolution process, both chemical and electrochemical
processes have to be considered.
According to the literature,17 the chemical dissolution
process corresponds to the oxidation of the aluminum
sheets with the simultaneous reduction of water to form
hydrogen, according to eq 1.

2Al + 6H2O f 2Al3+ + 3H2 + 6OH- (1)

On the other hand, the electrochemical processes that


Figure 9. (a) Influence of the salinity on the amount of aluminum occur on the anode and on the cathode surfaces are
electrodissolved: T, 25 °C; pH, 6.0; flowrate, 19.8 dm3 h-1; j, represented by eqs 2-4. On the anode, aluminum
0.5 mA cm-2. Supporting media: [ NaCl, 0 Na2SO4. (b) Influence dissolution and oxygen evolution can compete. On the
of the current density on the amount of aluminum electrodissolved
for the same passed electrical charge: T, 25 °C; pH, 6; passed
cathode, hydrogen evolution is the main expected reac-
electrical charge, 0.0028 A h dm-3. Supporting media: [ 2450 mg tion. As can be observed, in both the chemical and the
dm-3 NaCl; 0 3000 mg dm-3 Na2SO4.
Al f Al3+ + 3e- (2)
tion is maintained almost constant. On the other hand,
high current densities lead to less efficient processes. 2H2O f O2 + 4H+ + 4e- (3)
This fact can be explained in terms of the competition
between aluminum dissolution and oxygen evolution. H2O + e- f 1/2H2 + OH- (4)
At low values of current density, only the aluminum
dissolution exists, while at high values, both processes electrochemical processes, hydrogen is generated.
compete and, as a consequence, the aluminum genera- Once the aluminum is dissolved (chemically or elec-
tion efficiency decreases. trochemically), some species can be formed, depending
The differences observed between the experimental on the pH of the solution. The reactions involved are
results and those expected if the process was purely shown below19,20 (eqs 5-9). In this set of equations, the
electrochemical can be explained in terms of the chemi- following have also been taken into account: the
cal dissolution of the electrode surfaces. In the first carbonate/bicarbonate equilibria (eqs 10 and 11) and the
section of this discussion, it has been proven that ionization of water, because of its high influence on the
chemical dissolution of aluminum can be obtained under calculation of the pH value.
acidic or alkaline media, although the rate increases
strongly in the later conditions. The electrochemical
Al(OH)4- + H+ a Al(OH)3 (5)
oxidation and reduction of water can importantly modify
the pH on the anode and on the cathode surfaces with
respect to the bulk pH. This is specially important on
Al(OH)3 + H+ a Al(OH)2+ (6)
4182 Ind. Eng. Chem. Res., Vol. 44, No. 12, 2005

Al(OH)2+ + H+ a Al(OH)+2 (7)

Al(OH)+2 + H+ a Al3+ (8)

Al(OH)3(s) a Al3+ + 3OH- (9)

CO2 + H2O a H+ + HCO3- (10)

HCO3- a CO32- + H+ (11)

H2O a OH- + H+ (12)

The other important point in the model is the fluid


dynamic approach. As has been shown previously, the
pH has a strong influence in the chemical dissolution
process, and the value of this parameter can increase
by several order of magnitude at an alkaline pH. In each Figure 11. Scheme of the electrochemical reactor considered in
electrochemical cell, there is a pH profile between anode the model as the combination of three interconnected stirred-tank
and cathode. In the anode, the water oxidation process reactors.
(oxygen evolution) generates a high concentration of
protons and, thus, a lower pH must be obtained. In the segregated flow approach has been successfully dem-
cathode, the water reduction process results in the onstrated in the literature using marker-pulse tech-
formation of hydroxyl ions and a higher pH must appear niques for channel flow cells24.
in this zone. Thus, a marked pH profile is expected, and
The volume of each zone can be easily calculated25,26
the bulk pH is not a good value to determine the rate
if it is assumed that the thickness of the electrochemical
of chemical dissolution, because it must differ consider-
zone is equivalent to the Nernst diffusion layer (δ). This
ably from the actual values on the electrodes surfaces.
assumption is acceptable because direct oxidation and
To take this into account, the fluid dynamic model most of the mediated oxidation processes (those with
must consider this profile of pH. An exhaustive descrip- high reaction rates) occur in this zone. The thickness
tion of the electrochemical dissolution of aluminum of this zone can be evaluated as a function of the mass-
electrodes (in which the concentration profile of every transfer coefficient (k) and the diffusivity (D) using eq
compound in the electrochemical cell is calculated) is 13.
extremely difficult, because it would lead to a math-
ematical system involving several partial differential D
equations. This complex situation arises since the δ) (13)
k
concentration of every compound depends on time and
on the distance to the electrode surface. Such a system
would not be helpful because of its high degree of The electrode surface area is known, and so the volume
complexity, and therefore, in an attempt to achieve a of each electrochemical zone (Va and Vc) can be easily
useful model, a number of assumptions must be made calculated by multiplying it by the thickness (δ). The
in order to simplify the model. The assumptions that remaining volume of the system corresponds to the
are going to be taken into account have been previously volume of the chemical zone (Vb).
proposed in the literature in other works of our group,21,22 Mass transport processes between electrochemical
and they have helped to successfully represent waste- and chemical zones are quantified by assuming that the
water electrochemical oxidation processes.23 local exchange rate is proportional to the concentration
The first assumption is related to the description level difference between the two zones. The mass-transfer
of the process. The position-dependence of the model can rate can be calculated from eq 14, where [Si]* and [Si]
be simplified by dividing the electrochemical reactor into are the concentrations (mol m-3) of component i in the
electrochemical and the chemical zones, respectively, k
three zones: two zones (electrochemical zones) close to
(m s-1) is the mass-transfer coefficient, and A (m2) is
the electrodes (anode and cathode) and a third zone
the specific interfacial area between the electrochemical
corresponding to the bulk solution (chemical zone). In
and chemical zones. The mass-transfer coefficient (k)
these three zones, the concentration of every compound
can be assumed to depend only on the flow rate
is considered to be constant with position and only time-
conditions, because the concentrations of the compounds
dependent. This assumption is valid if the residence
are low.
time in the electrochemical cell is small, since, in this
case, the profiles of concentration in the flow direction
can be assumed to be negligible. The concentration of ri ) kA([Si]* - [Si]) (14)
each compound in the chemical zone is taken as the
value measured experimentally. The concentration in The assumption of dividing the electrochemical cell
the electrochemical zone is supposed to have a value into several zones allows the simplification of the
between the concentration at the electrode surface and mathematical complexity of the model. Thus, the com-
the concentration in the chemical zone. plex system of partial differential equations (obtained
Hence, the electrochemical reactor is modeled as the from the mass balance in a nonsimplified system) is
combination of three interconnected stirred-tank reac- reduced to an easier-to-solve system of ordinary dif-
tors, as shown schematically in Figure 11. This highly ferential equations.
Ind. Eng. Chem. Res., Vol. 44, No. 12, 2005 4183

d[Si]a [Al(OH)3]z[H+]z
Va ) kA([Si]b - [Si]a) + relectrochemi,a + rchemi,aVa ) 10-5.7 (21)
dt [Al(OH)2+]z
(15)
d[Si]c [Al(OH)2+]z[H+]z
Vc ) kA([Si]b - [Si]c) + relectrochemi,c + rchemi,cVc ) 10-4.3 (22)
dt [Al(OH)2+]z
(16)
d[Si]b [Al(OH)2+]z[H+]z
Vb ) q([Si]0 - [Si]b) + kA([Si]a - [Si]b) + ) 10-5.0 (23)
dt 3+
[Al ]z
kA([Si]c - [Si]b) + rchemi,bVb (17)
[HCO3-]z[H+]z
The kinetic rate of the electrochemical processes, limited ) 10-6.37 (25)
by the applied current density (I), is given in eq 18, [H2CO3]z
where F is the Faraday constant.
[CO32-]z[H+]z
I ) 10-10.25 (26)
r) (18) [HCO3 ]z-
F
On the cathode, only hydrogen evolution is supposed [H+]z[OH-]z ) 10-14.0 (27)
to develop. Thus, eq 18 can be used to represent this
process. On the anode, both aluminum electrodissolution
and oxygen evolution compete. To model this, the

anionic species
n[An-]z - ∑
cationic species
m[Bm+]z ) 0 (28)
fraction of current employed to oxidize each of these
compounds can be assumed to be directly related to the [TDA]z ) [Al3+]z + [AlOH2+]z + [Al(OH)2+]z +
overpotential of the two compounds (ηAl and ηO2). This
approach has been used successfully as reported in the [Al(OH)3]z + [Al(OH)3]sol,z + [Al(OH)4-]z (29)
literature in previous works of our group.21-23
[IC]z ) [H2CO3]z + [HCO3-]z + [CO32-]z (30)
I ηi
relectrochemi ) (19)
Figure 12 shows the time variation of pH and alumi-
∑j ηj
F
num concentration calculated from the model compared
to those obtained experimentally for three different
experimental assays. It can be observed that the model
To obtain the chemical dissolution rate that appears on fits well the experimental data, with average errors
both equations, the data of Figure 5 have been fitted to <5% for the reproducibility of pH and <10% for the
an empirical equation. reproducibility of the aluminum concentration.
The Euler method was used to solve the system of Figures 13 and 14 show the experimental steady-state
differential equations. The aluminum dissolved from the values of aluminum and bulk pH as a function of both
electrodes can be present as different species depending the initial solution pH and the specific passed electric
on the pH of the media. The concentration of any of charge (for a constant flowrate) compared to the values
these species depends on the total concentration of obtained from the model. It can be observed that there
dissolved aluminum and on the pH, and this makes the is great reproducibility of the experimental results in
system complex from the mathematical point of view both the pH and the aluminum concentration, with
and, consequently, difficult to solve. To simplify the average regression coefficients (r2) of 0.920 and 0.958
calculations, eqs 15-17 were applied only to a unique for aluminum and pH, respectively. This validates the
aluminum species (the total dissolved aluminum, TDA) assumptions on which the model is based.
and to the hydroxyl and protons. For each time step (of
the Euler differential-equations-solving method), the
different aluminum species and the resulting proton and Conclusions
hydroxyl concentration in each zone were recalculated
using a pseudoequilibrium approach. To do this, the The following conclusions can be drawn from the work
equilibrium equations (eqs 20-27), the charge (eq 28), described here:
and the aluminum (eq 29) and inorganic carbon (IC) 1. The aluminum dissolved in an electrochemical cell
balances (eq 30) were considered in each zone (anodic, comes from both chemical and electrochemical pro-
cathodic, and chemical), and a nonlinear iterative cesses. The chemical process contribution is often more
procedure (based on an optimization method) was important than that of the electrochemical process
applied to satisfy simultaneously all the equilibrium 2. The chemical dissolution of aluminum is strongly
constants. In these equations (eqs 20-30), subindex z influenced by the pH. Alkaline pHs increase the dis-
stands for the three zones in which the electrochemical solution rate by orders of magnitude. Within the ex-
reactor is divided (anodic, cathodic, and chemical). perimental conditions used, the supporting media does
not seem to greatly influence the chemical dissolution
[Al(OH)4-]z[H+]z process.
) 10-8.0 (20) 3. The electrochemical dissolution process depends
[Al(OH)3]z
mainly on the specific passed electrical charge. The
salinity and the nature of the ions do not seem to
[Al3+]z[OH-]z3 ) 10-32.9 (24) significantly affect the electrodissolution rate.
4184 Ind. Eng. Chem. Res., Vol. 44, No. 12, 2005

Figure 12. Experimental and modeled variation of aluminum Figure 14. Influence of the specific passed current charge.
concentration and bulk pH with time for three experimental assays Experimental and modeled steady-state values of aluminum
at different initial pH (T, 25 °C; j, 0.5 mA cm-2; flowrate, concentration and bulk pH (T, 25 °C; pH, 6.0; flowrate, 19.8 dm3
19.8 dm3 h-1): [ 2450 mg dm-3 NaCl, pH 11; 0 3000 mg dm-3 h-1). Supporting media: [ 2450 mg dm-3 NaCl, 0 3000 mg dm-3
Na2SO4, pH 11; 2 2450 mg dm-3 NaCl, pH 4; O 3000 mg dm-3 Na2SO4. The continuous line indicates results obtained from the
Na2SO4, pH4; s 2450 mg dm-3 NaCl, pH 1; × 3000 mg dm-3 model.
Na2SO4, pH 1. The continuous line indicates results obtained from
the model.
Acknowledgment
This work was supported by the MCT (Ministerio de
Ciencia y Tecnologı́a, Spain) and by the EU (European
Union) through project CTM2004-03817/TECNO. The
contribution of Junta de Comunidades de Castilla La
Mancha is also acknowledged for the grant of F.M.

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