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Journal of Cleaner Production 228 (2019) 1e7

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Journal of Cleaner Production


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Surfactant-assistant atmospheric acid leaching of laterite ore for the


improvement of leaching efficiency of nickel and cobalt
Peiyu Zhang a, Linquan Sun a, Hairui Wang b, Jiwei Cui a, Jingcheng Hao a, *
a
School of Chemistry and Chemical Engineering, Shandong University, Jinan, Shandong 250100, China
b
Shandong Environmental Protection Industry Group Co., LTD, Jinan, Shandong 250000, China

a r t i c l e i n f o a b s t r a c t

Article history: Atmospheric acid leaching has attracted great attention from scientists due to the mild leaching con-
Received 29 December 2018 ditions. However, the leaching efficiency of nickel is lower than that using high pressure acid leaching.
Received in revised form Herein, we report the use of a surfactant (e.g., stearyltrimethyl ammonium chloride, STAC) to improve
20 March 2019
the leaching efficiency of Ni. The effects of surfactant type, ore-surfactant ratio, leaching temperature,
Accepted 23 April 2019
Available online 24 April 2019
and leaching duration on the leaching ratio of Ni were investigated. The use of STAC resulted in the high
efficiency for Ni leaching at 100  C with an ore-surfactant ratio of 15 and leaching duration of 8 h. The
leaching efficiencies of Ni and Co were significantly higher than that of atmospheric acid leaching. The
Keywords:
Atmospheric acid leaching
surface tension and viscosity of the leaching solution, and the zeta potential of the leached residue were
Surfactant analyzed to investigate the mechanism of the leaching process. The changes of interfacial properties
Ni improved ionic diffusion and decreased metal adsorption, which further lead to the increasing of
Laterite ore leaching efficiency.
© 2019 Elsevier Ltd. All rights reserved.

1. Introduction and Gerson, 2013; MacCarthy et al., 2015a, b). The long leaching
duration and high leaching ratio of Fe restrict the utilization of this
Acid leaching is one of the hydrometallurgical methods for Ni process.
extraction from laterite ores, which includes high pressure acid The low leaching efficiency may be caused by the adsorption of
leaching (HPAL), heap leaching (HL), and atmospheric acid leaching Ni and low mineral dissolving rate. To improve the mineral dis-
(AL) (Ma et al., 2017; MacCarthy et al., 2014; Oxley et al., 2016). solving rate of AL, some attempts, such as adding of reducing
Although these processes have been used in industrial scale, the agents, changing the method of heating, and pretreating laterite
related disadvantages restrict the development of the processes or ore, have been reported (Bobicki et al., 2014; Che et al., 2010; Luo
increase the cost of the production. For example, nickel and cobalt et al., 2015). For example, Senanayake et al. used SO2 and Cu(II)
can be selectively leached from laterite ore in the HPAL process, as reducing agents to promote the leaching of valuable metals and
nevertheless, the severe leaching conditions (250  C, 4e5 MPa), decrease the leaching time (Senanayake et al., 2015). Sulfites were
high cost of equipment, and easy-forming fouling lead to high cost also added to strengthen the leaching and decrease the polution of

and interrupted operation (Onal and Topkaya, 2014). HL is used to SO2 (Basturkcu and Acarkan, 2016). Pinto et al. utilized microwave
leach valuable metals by spraying acid at the top of the ore heap, to heat the leaching suspension for volumetric heating and fast
whose operation measures are simple (Nosrati et al., 2014; Quaicoe processing (Pinto and Soares, 2013). To liberate the minerals and
et al., 2013, 2014; Quast et al., 2013). However, the acid consump- expose Ni, alkalis or mechanical activation were used to pretreat
tion is even higher than that of HPAL, and the high concentration of laterite ores (Basturkcu et al., 2017; Wang et al., 2013, 2014).
Fe ions in the leaching solution make the post treatment process Therefore, the use of appropriate agents or changing reaction
complexed. AL is operated under the boiling point of lixiviants and conditions could increase the leaching ratio of Ni and decrease the
atmospheric pressure, which leads to a low leaching kinetics (Fan leaching duration. However, seldom researches focused on the
decreasing of adsorption to increase the leaching ratio Ni.
The crystalline structure, surface roughness, and other factors
usually results in some minerals being not neutral (Carlson and
* Corresponding author. Kawatra, 2013). Thus, electrostatic interaction may result in the
E-mail address: jhao@sdu.edu.cn (J. Hao).

https://doi.org/10.1016/j.jclepro.2019.04.305
0959-6526/© 2019 Elsevier Ltd. All rights reserved.
2 P. Zhang et al. / Journal of Cleaner Production 228 (2019) 1e7

adsorption of Ni by the leached residue (Uddin et al., 2012). Another analyzing the leaching ratio of valuable metals by using AAS. The
cation could be added into the leaching solution to decrease the leaching solutions were also sampled to analyze the surface tension
adsorption of Ni by competitive adsorption (Vocciante et al., 2018; and viscosity. The residues were dried in the oven before they were
Coelho et al., 2016). Surfactants are a type of molecules that consists used in the phases’ analysis and the zeta potential measurements.
of both hydrophilic and hydrophobic groups, which have been used
in chemical cleaning products, medicine, and flotation. Surfactants 3. Results and discussion
are used to separate concentrate and gangue in beneficiation by the
different of electrostatic forces between the three materials 3.1. Element and phase analysis
(Filippov et al., 2014). Therefore, we hypothesized that the loss of Ni
could be decreased by adding surfactant during acid leaching. Be- The main components of laterite ore are listed in Table 1. The
sides, the presence of surfactants could change the physiochemical contents of Ni and Co in the laterite ore were 1.14% and 0.09%. The
properties of surface and interface, which may further change the contents of Fe2O3, MgO, and SiO2 were 21.57%, 27.83%, and 30.12%,
mass transfer. Thus, common surfactants were chosen as the ad- respectively, which indicated that the laterite ore was saprolitic
ditives to decrease the cost of the process. laterite ore. According to the XRD spectra showed the main phase of
In this work, surfactants were added to sulfuric acid during at- the ore (Fig. 1a), the laterite is mainly consisted of clinochrysotile,
mospheric acid leaching for increasing the leaching efficiency of Ni. goethite, and quartz, which further indicated that this laterite was a
The effects of surfactant to ore ratio, temperature, and leaching typical saprolitic laterite ore. The crystallinity of the phase is weak,
time on the leaching of Ni were investigated. To identify the which may be caused by the weathering and leaching of laterite
leaching mechanism, the zeta potential of the leaching residues and ore. After acid leaching with or without STAC, the peak intensity of
surface tension of leaching solution were analyzed. The positive the XRD spectrum decreased, which indicates the decomposing of
zeta potential of leaching residues decreased the adsorption of Ni the laterite ore. Since Ni and Co existed in goethite and clinochry-
on the surface of particles, and the low surface tension of leaching sotileby adsorption and lattice replacing, the disintegration of
solution improved the diffusion of lixiviant. laterite ore improved the leaching of valuable metals. Fig. 1a also
shows that clinochrysotile decomposed more easily than goethite.
2. Experimental
3.2. Zeta potential analysis
2.1. Materials
As mentioned above, electrostatic adsorption is one of the main
Laterite ore used in this study was obtained from Philippine
reasons that result in the loss of Ni. The zeta potential suggests the
laterite deposit. Dodecyl trimethyl ammonium chloride (DTAC),
surface charge of particle, which affects the adsorption of metal
tetradecyl trimethyl ammonium chloride (TTAC), cetyltrimethyl
ions on particle. Thus, the leaching ratio of Ni may increase by
ammonium chloride (CTAC),stearyltrimethyl ammonium chloride
controlling the zeta potential of particles. The zeta potentials of
(STAC), dodecyl dimethyl benzyl ammonium chloride (DDTAC)
laterite ore in water were 9.0 mV and 9.8 mV after 0.5 and 6 h of
were purchased from Shanghai Macklin Biochemical Co., Ltd. Hy-
agitation, respectively (Table 2). The negative surface charges may
drochloric acid was purchased from LaiyangKangde Chemical Plant.
be caused by the defects of the crystals. Positively charged ions (e.g.,
All these reagents were analytical grade and were used without
Ni2þ and Co2þ) can be absorbed by laterite ore (Maiti et al., 2007),
further purification. Sulfuric acid was purchased from Laiyang
which may lead to the low leaching ratio. The zeta potential of
Economic and Technological Development Zone Fine Chemical
laterite ore in water with STAC (water system) were 32.0 and
Plant and was of guaranteed reagent.
33.6 mV after 0.5 and 6 h of stirring, respectively (Table 2), which
indicated that STAC could be adsorbed on the surface of laterite ore.
2.2. Apparatus
The main force of this process is electrostatic and hydrophobic
interactions. The zeta potential reversed and the potential process
Element analysis was implemented by using atomic absorption
is showed in Fig. 1b. In traditional system, the zeta potential of
spectrophotometry (AAS, TAS-990, Beijing Purkinje General In-
leached residue was negative. However, it was higher than the zeta
strument Co., Ltd.). The phase compositions of laterite ore were
potential of ores, which indicated the adsorption of metal ions on
analyzed by X-ray diffractometer (XRD, D8 ADVANCE, Bruker). The
the surface during leaching. As the results above, the zeta potential
zeta potentials of laterite ore and leached residues were measured
of particles could be controlled by adding cation surfactants. The
by dynamic light scattering (NanoZS, Malvern). The surface tension
zeta potential of leached residue may also be changed by adding
was analyzed by automatic interface tensiometer (Beijing Time Top
cation surfactant. Thus, DTAC, TTAC, CTAC, STAC, DDTAC were used
Technology Co., Ltd.). The viscosity of lixiviant was detected by
as adding reagents to leach laterite ore by atmospheric sulfuric acid
rotor viscometer (DV-II þ Pro, Brookfield).
leaching. As can be seen from Fig. 1c, the zeta potentials of leached
residues are higher than the leached residue of traditional system.
2.3. Experimental procedure
Besides, the zeta potential increased as the increase of the chain
length, which may be caused by the stronger hydrophobic in-
The ore was ground with an average size of 74 mm with a pul-
teractions of longer chain surfactants. The zeta potential of the
verizer before blending. The powder of laterite ore was dried in an
leached residue based on DTAC was about 2.2 mV, which may
oven at 60  C overnight. A certain amount of surfactant (according
result in the adsorption of Ni on the surface of the residue.
to the ore-surfactant ratio) and 8% sulfuric acid were mixed before
To investigate the changing of zeta potential during the whole
they were agitated with dried laterite ore in 50 mL centrifuge tubes.
The rotational speeds of magnetons were set at 1200 rpm to insure
the slurries suspended uniformly. The centrifuge tubes were placed Table 1
in an oil bath with a thermostat to control the temperature of the The main components of laterite ore.
slurries. After the reaction, the tubes were centrifuged (3e30ks, Element Ni Co Fe2O3 MgO SiO2 Al2O3
SIGMA) to separate pregnant solutions with residues. Then, the
Content (wt.%) 1.14 0.09 21.57 27.83 30.12 1.22
pregnant solutions were diluted to certain concentrations for
P. Zhang et al. / Journal of Cleaner Production 228 (2019) 1e7 3

Fig. 1. XRD of laterite ore and leached residue (a), zeta potential of particles in different system (b), effect of surfactant on the zeta potential of the leached residues (c), the effect of
leaching time on the zeta potential of the leached residues (d).

Table 2 the positive zeta potential.


Zeta potential (mV) of laterite ore in water and water solution of STAC. In STAC system, the zeta potential was positive. However, the
Time (h) water STAC water solution value was smaller than that of water system. The reason why the
0.5 9.0 32.0
zeta potential of the residue in STAC system was lower than that in
6 9.8 33.6 water system may be because of the following point. The reason
may be the competitive adsorption between STAC and cations
(Fig. 1b), which led less STAC to be adsorbed on the surface of
leaching process, further experiments based on STAC system were residue. The hydrophobic interaction between STAC was weaker,
determined (Fig. 1d) because of the highest zeta potential. The zeta and less cationic groups were exposed compared with that in the
potential of the residue after 0.5 h leaching using sulfuric acid with water system. Thus, the competitive adsorption made the zeta
STAC was 13.5 mV, which was higher than that in the traditional potential in STAC system lower than that in the water system. More
system. This indicated that STAC adsorbed on the particles quickly important, the presence of competitive between STAC and cations
and decreased the adsorption of Ni at the beginning of leaching. may decrease the loss of Ni. Thus, different kinds of surfactants
The values of the potential were positive during the whole leaching were used as additives during leaching to confirm that leaching
process, which suggested that surfactant may decrease the ratio of Ni could be increased.
adsorption of Ni during the process. In contrast, the zeta potential
of the residue after 0.5 h leaching using sulfuric acid was 1.0 mV. 3.3. The effect of surfactant types on the leaching ratio of Ni
The values of potential were negative during the whole traditional
leaching process, which were lower than that in the STAC system. The Ni leaching ratios based on different surfactants is showed
This indicated that zeta potential of particles could be changed by in Fig. 2a. The Ni leaching ratios of surfactants systems (except
adding STAC. Thus, the positive potential of particles in STAC system DTAC system) were higher than that of traditional system. The
may result in the higher leaching ratio of Ni than that of traditional leaching ratio of Ni was 64.9% after 6 h of leaching in 8 wt% sulfuric
system. The leaching ratio of Ni based on other surfactants (except acid, and with a liquid-solid ratio (v/w) of 10 at 90  C. Whereas, the
DTAC system) may also be larger than traditional system because of leaching ratio of Ni was 70.1%, 65.3%, 79.0%, 72.1% at ore-surfactant
4 P. Zhang et al. / Journal of Cleaner Production 228 (2019) 1e7

Fig. 2. Effect of surfactant types on the leaching ratio of Ni (a), effect of ore-surfactant ratio on the leaching ratio of Ni (b).

of 10 under the same condition for TTAC, CTAC, STAC, and DDTAC For the leaching of different metals, Co was leached more easily
systems, respectively. The Ni leaching was 38.6% when DTAC was compared with Ni. Fig. 3b shows that the Co leaching ratio of
added into the lixiviant, this may be caused by the increase of the traditional leaching system was more than 74.9% when the laterite
lixiviant viscosity. The results confirmed that the leaching ratio of ore was leached at 60  C, and increased to 83.7% at 90  C after 6 h of
Ni could be changed by adding surfactants. In DTAC system, the leaching. Fig. 3b also shows that the existing of STAC during at-
unchanged zeta potential was one of the main reasons that result in mospheric acid leaching improved the leaching ratio of Co. The
the lower leaching ratio of Ni compared with traditional system. In leaching ratio of Co increased by 8.3% when STAC was added into
contrast, the high zeta potential decreased adsorption and the leaching lixiviant at 60  C. More than 91.3% of Co could be
improved the leaching ratio of Ni in other systems. Thus, STAC was leached at 90  C, and the Co leaching ratio of the STAC system is
selected as adding reagent in the following experiments because of 7.6% higher than that of the traditional system at 90  C. Fig. 3a and b
the highest leaching ratio. demonstrate that the leaching ratio of Co was also higher than that
of Ni in the STAC system. Since the approximately equal solubility
products of the two metals hydroxides (Yavuz et al., 2003), the low
3.4. The effect of ore-surfactant ratio on the leaching ratio of Ni
concentration of Co in the leaching solution may result in the easy
leaching of Co.
Fig. 2b shows the changes of the leaching ratio of Ni with the
Fig. 3c illustrates that the Fe leaching ratio of traditional leach-
increase of ore-surfactant ratio at the temperature of 90  C, leach-
ing system increased from 24.6% to 33.5% as the leaching temper-
ing duration of 6 h, and liquid-solid ratio of 10 (v/w). The leaching
ature increased from 60  C to 100  C. However, Fe expressed a
of Ni increased from 74.8% to 79.1% as the ore-surfactant ratio
different leaching behavior compared with that of Ni and Co when
increasing from 1 to 5, and it remained constant as the ratio
STAC was added into the lixiviant. The leaching ratio of Fe based on
increased to 15. However, when the ore-surfactant ratio increased
STAC was lower than the Fe leaching of traditional system. The
from 15 to 30, the Ni leaching decreased from 79.3% to 71.7%. Few
former decreased to 17.5% when laterite ore was leached with STAC
amount of STAC changes the zeta potential of ore surface and im-
at 60  C. Although, the Fe leaching increased as the temperature
proves the diffusion ions, which may promote the increase the
increased, it still remained lower than that of the traditional sys-
leaching ratio of Ni. However, excessive STAC may cause a pykno-
tem. Therefore, the presence of STAC improved the leaching
morphic adsorbed layer and viscous lixiviant, which restrict the
selectivity of Ni and Co. The selectivity is better at lower temper-
diffusion of ions. Considering the leaching ratio of Ni and the cost of
atures because of the lower concentration of Fe in the leaching
the process, the optimal ore-surfactant ratio was chosen as 15 and
solution. However, the leaching ratio of valuable metals was also
was used in the following experiments.
low. In consequence, 100  C was chosen as the optimal leaching
temperature.
3.5. The effect of temperature on the leaching ratio of valuable
metals
3.6. The effect of leaching duration on the leaching ratio of metals
The Ni leaching of the two systems shows distinct leaching
regular patterns (Fig. 3a). The leaching ratio of Ni in the STAC sys- Fig. 4a indicates that the leaching behaviors of Ni in the two
tem is higher than that of the sulfuric acid system when the tem- systems were different while changing the leaching times. The
perature is between 60  C and 90  C. Fig. 3a shows that the Ni leaching ratio of Ni increased from 55.4% to 63.2% as the leaching
leaching ratio based on STAC did not change significantly when the duration varied from 0.5 to 5 h when laterite ore was leached with
leaching temperature was increased from 60  C to 70  C, and sulfuric acid, and decreased to 56.6% after 8 h of leaching. This may
increased rapidly at higher temperatures. For example, the leaching be a consequence of the adsorption of Ni by leached residue. The
ratios of Ni were 67.5% and 87.5% at 80 and 100  C, respectively. The leaching ratio of Ni in STAC system was 51.5% at the beginning of the
Ni leaching of traditional leaching system increased much more process, which was comparable with the traditional system. Even
slowly when the leaching temperature was changed at the same though the Ni leaching of the STAC system exceeded the Ni leaching
conditions. of traditional system after 2 h, it quickly increased from 62.7% to
P. Zhang et al. / Journal of Cleaner Production 228 (2019) 1e7 5

Fig. 3. The effect of temperature on the leaching ratio of Ni (a), the leaching ratio of Co (b), and the leaching ratio of Fe (c).

Fig. 4. The effect of leaching time on the leaching ratio of Ni(a), the leaching ratio of Co (b), and the leaching ratio of Fe (c).

79.3% from 4 to 6 h, and reached 84.0% after 8 h of leaching. The Thus, the viscosities of leaching solutions were investigated by a
kinetics was different in the first 4 h and the latter, which showed rotor viscometer to determine the effect of viscosity on the leaching
different kinetics with atmospheric acid leaching. This may be due ratio of valuable metals (Fig. 5a and b). Firstly, the viscosities of the
to the presence of STAC in the lixiviant. leaching solutions with different surfactants were detected. The
The Co leaching ratio of traditional leaching system did not viscosities were almost the same after 8 h leaching, which indicated
change significantly during the 8 h of leaching (Fig. 4b). The that the type of the surfactants has little effect on the mass transfer
leaching ratio of Co in the STAC system was 75.5% at the leaching (Fig. 5a). Then, the effect of leaching time on the viscosity was
duration of 0.5 h, which is lower than that of the traditional system. determined based on STAC system (Fig. 5b). At the beginning of the
However, it increased to 83.2% and exceeded the traditional system leaching, the viscosity of the atmospheric acid leaching solution
when the laterite ore was leached at 1 h. The Co leaching in the was 1.40 cp, which was lower than that of the STAC leaching so-
STAC system reached the plateau after 5 h. The slow leaching ki- lution. The higher viscosity of the leaching solution led to the
netics of the STAC system in the first 0.5 h may also be caused by the slower mass transfer, and made the leaching ratio of Ni lower
presence of STAC. compared with the traditional leaching process. The viscosity of the
The leaching ratio of Fe in the traditional leaching system atmospheric acid leaching solution increased quickly, and was
increased from 21.5% to 34.5% as the leaching duration increased similar to that of the STAC system after 2 h of leaching. The viscosity
from 0.5 h to 8 h (Fig. 4c). It was greater than Fe leaching in the STAC of the solution is no longer the main factor that influences the
system. The latter increased from 18.0% to 33.8% in the same time leaching ratio of valuable metals.
range. The presence of STAC may cause the leaching ratio of Fe to The surface tension affects the wettability of leaching solution,
decrease. The reason may be caused by the adsorption of Fe com- which further affects the diffusion of ions. To analyze the effect of
plex (e.g. FeCl
4 ) on the surface of particles, which formed by the surfactant type on surface tension, it was investigated by an auto-
anion of STAC and leached Fe3þ. The selectivity of valuable metals matic surface tensiometer. The surface tension based on DTAC was
was improved due to the increase of valuable metal leaching and 46.0 mN/m, which indicated the poor wettability of the leaching
the decrease of Fe leaching. After a systematic consideration, the solution (Fig. 5c). However, the leaching solutions based on STAC
optimal leaching duration was determined to be 8 h. and DDBAC showed good wettability because of the low surface
tension. The low surface tension of STAC and DDBAC systems was
3.7. Effect of surfactant on the leaching process one reason that the leaching ratio of Ni was higher than traditional
and DTAC systems. To further analyze the effect of surfactant on the
The surfactants may also change the physiochemical properties leaching ratio, the surface tension was detected at different leaching
of the leaching solution, which may also affect the leaching ratio. time based on traditional system and STAC system. The surface
Thus, the viscosity and surface tension of leaching solutions were tension was 63.1 mN/m after 0.5 h of leaching with sulfuric acid and
detected. increased due to the increase of the metal sulfate in the leaching
The high viscosity has a detrimental effect on the mass transfer. solution (Fig. 5d) (Tuckermann, 2007). The high surface tension of
6 P. Zhang et al. / Journal of Cleaner Production 228 (2019) 1e7

Fig. 5. The effect of surfactant on the viscosity (a) and surface tension (c) of the leaching solutions, the effect of leaching time on the viscosity (b) and surface tension (d) of the
leaching solutions.

the leaching solution may lead to the decrease of wettability of Ni and Co exceeds that of the traditional leaching system (Fig. 4a).
lixiviant on the particles surface and prevent the lixiviant to enter
the cracks of particles, which may be one reason causing the low 4. Conclusion
leaching rate of valuable metals. Because the presence of STAC, the
surface tension of the STAC system was lower than that of the The addition of surfactants into lixiviant can improve the
traditional system during the whole leaching processes. The low leaching ratio of Ni and Co. STAC showed a better stimulation on the
surface tension improved the wettability of lixiviant, and promoted leaching ratio compared with other surfactants. Our experiments
the leaching of valuable metals. At the beginning of the leaching, the indicate that ore-surfactant ratio of 15, leaching temperature of
viscosity was the main factors which affected the leaching ratio of 100  C, and leaching time of 8 h are the optimal conditions for
Ni; however, the surface tension became to be the main factor after leaching of Ni and Co. The viscosity is the peripheral element
about 1 h of leaching. Thus, the leaching kinetics of valuable metals affecting the leaching ratio. The surface tension of the leaching
based on STAC showed two stages because of the presence of STAC. solution in STAC system was lower than that in the traditional
The improvement of Ni and Co leaching may be due to the leaching system, which was beneficial for the entry of the lixiviant
following factors. Firstly, the surface tension of the STAC leaching to the internal of the particles. The zeta potential of the leached
solution is lower compared with that of the traditional leaching residue reversed because of the existing of STAC, which can
solution. The lower surface tension can promote the lixiviant to decrease the adsorption of valuable metals. Therefore, the use of
enter the crevices of the granule, which may be beneficial for mass appropriate surfactants in the leaching process is promising to
transfer. Secondly, the surfactant can enter into the cracks of the ore improve the leaching ratio for valuable metals in the practical ap-
particles like a wedge, and liberate the particles to small granules. plications. Overall, the leaching ratio of Ni and Co increased when
Compared with larger particles, the smaller ones have larger spe- STAC was added into the lixiviant.
cific surface areas, which is beneficial for the reaction. Lastly, the
competitive adsorption between surfactant and valuable metals Acknowledge
decrease the adsorption of Ni and Co, and thus improve the
leaching ratio. Therefore, after 2 h of leaching, the leaching ratio of This work was financially supported by the National Natural
P. Zhang et al. / Journal of Cleaner Production 228 (2019) 1e7 7

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