Over-compacting should be avoided to avoid segregation. In the airdrop, the raw meal is lifted to the storehouse by packed air to the air slide and then put away and homogenized in a solid storehouse. At that point this slurry is siphoned into slurry tanks or bowls. Alumina imparts quick setting property. Hence, cement should be stored on a raised platform in a covered room. In that tank, the limestone and mud particles are forestalled to settle by blowing packed air from the lower part of slurry are kept in touched off condition with assistance of pivoting arms with chains. classified as fine sand, coarse sand, and gravelly sand. THE CEMENT MANUFACTURING PROCESS Prof. Dr Elshafie Ahmed Gad Faculty of Applied Science Chemistry Dept. water is mixed gradually while the mixing process is kept continuous. 5. A limestone quarry is inside the plant zone and a muds quarry is a long way from the plant territory as 25 km. It allows the carbon dioxide from the air to penetrate and improve the setting. The dry process requires considerably less fuel as the materials are as of now in a dry state, while in the wet process the slurry contains around 35 to 50 percent water. The fine material, called raw meal, is gathered from the multi-tornado and then taken care of into an air slide for lifting called an Aeropol. At that point the preheated furnace feed is halfway calcined (made fine) in an ignition chamber and riser pipe and then totally calcined in a rotational oven just as warmed to around 1400 C to shape clinker parts C3A, C4AF, C2S, and C3S. The clinker is put away in storehouses or receptacles. Limestones containing 20 to 40 percent clay may be burnt and crushed to powder to get natural. 11.6 Portland Cement Manufacturing 11.6.1 Process Description1-7 Portland cement is a fine powder, gray or white in color, that consists of a mixture of hydraulic cement materials comprising primarily calcium silicates, aluminates and aluminoferrites. dry mixed, then cement is mixed till uniform color is seen to the dry mix. Cement is a cover material which makes a bond between aggregates and reinforcing materials. A limestone quarry is inside the plant area and a clays quarry is as far from the plant area as 25 km. There are more than twenty types of cement used to make various specialty concrete, however the most common is Portland cement. At that point, it is stacked by a limestone stacker into a longitudinal storage unit called the limestone storage reserve. • The various tests conducted on coarse aggregates are to determine: Cement concrete is an intimate mixture of cement, sand, coarse aggregates, and water. The limestone is uncovered from open cast mines in the wake of penetrating and impacting and stacked onto unloaders which transport the materials and empty into containers of limestone smashers. The furnace is terminated from the lower end. Binding means it has an effect of gluing the substances together due to cohesive and adhesive action and then hardens and sets in order to become permanent. CEMENT MANUFACTURING PROCESS ! Likewise tried in the distinctive stockpiling tanks by mixing the slurry. At that point, the clinker is cooled under controlled conditions in a rotational cooler. This property, of setting as quickly as possible is achieved by following controls in the manufacturing process: Types of Manufacturing of cement There are two processes known as “wet” and “dry” processes depending upon whether the mixing and grinding of … If you have any doubt question suggestion Please Comments us or Email and Join on Social Media. From the limestone quarry to the conveyance of the finished result, follow each progression in the cement manufacturing process. The chemical process for hydraulic cement was found by ancient Romans who used volcanic ash (pozzolana) with added lime (calcium oxide). Evolution of the cement Process • Wet process easiest to control chemistry & better for moist raw materials. There are two types of cement manufacturing process known as “wet” and “dry” processes relying on whether the blending and granulation of raw materials are done in wet or dry conditions. The length of the turning furnace may differ from 30 meters to 200 meters. In the advanced technique for granulating, a very much evaluated cement molecule is shaped by the molecule size circulation of cement particles. The cement manufacturing process begins from the mining of raw materials that are utilized in cement manufacturing, predominantly limestone and muds. The cement manufacturing process starts from the mining of raw materials that are used in cement manufacturing, mainly limestone and clays. The cement manufacturing process is given here in detail: manufacturing of cement. Wet process The process to be chosen, depend onthe nature of the used raw materials. It is made of a thick steel cylinder of diameter anything from 3 meters to 8 meters, lined with refractory materials, mounted on roller bearings and capable of rotating about its axis at a … grading, bulking and to find fineness modulus. The specific heat consumption of modern plant ranges 690 to 800 Kcal/kg clinkers. These are rapid-hardening cement (RHC), quick-setting cement (QSC), low-heat cement (LHC), sulphate-resisting cement (SRC), blast furnace slag cement (BFSC), high-alumina cement (HAC), white cement (WC), coloured cement (CC), pozzolanic cement (PzC), air … Portland Cement Portland cement is made by mixing substances containing CaCO3 with substances containing SiO2, Al2O3, Fe2O3 and heating them to a clinker which is subsequently ground to powder and mixed with 2-6 % gypsum Raw Materials Necessary for Portland Cement Manufacture … At that point the drying materials enter the grinding office of raw plants for fine grinding. Jul 9, 2020 cement manufacturing process, cement production process, clinker, flow diagram of cement production, manufacturing process of cement by wet process, preheating tower Cement is the most significant material used in construction and it acts as a binder that can adhere to the materials. Cement is one of the most important building materials at the present time. FEUL TYPES. The plant must minimize the transportation cost since one third of the limestone is conv… Such raw materials are limestone, clay and sand. With a little change in the above process, we have the semi-dry process likewise where the raw materials are ground dry and afterward blended in with around 10-14 percent water and further consumed to clinkering … That dry force is additionally mixed, rectified for the correct structure and blended in with the progression of compacted air. Various admixtures used with concrete are: Important properties of concrete in the plastic stage (green concrete) are workability, segregation, and. oxide provides color, hardness, and strength. The increase in volume is as high as 30 – 37 percent, At around 8% of moisture content, there is maximum bulking. The dirts are uncovered from open cast mines and stacked onto unloaders which transport the materials and empty into open yard storage. It is, due to the formation of thin films around sand particles. For the most part, the clinker weighs around 1100 to 1300 gms for every liter. Petroleum gas is terminated as a principle fuel (100 %) in the fundamental burner turning furnace and a 95% flammable gas and 5.0% substantial oil blend in the ignition chamber. According to the requirement, cement has been manufactured in multiple types by altering its raw material and the manufacturing process. In current innovation, they utilize the hardware, for example, a cross belt analyzer made by Gamma-Metrics of USA to discover the synthesis of limestone at the transport lines, high-pressure twin roller press, six-stage preheater, and vertical roller factory. Evolution of combined water in the argillaceous components 3. If, FM is between 2.20 and 2.60 it is fine sand, 2.6 to 2.9 FM indicates it is medium sand and more, • For structures like abutment, retaining walls, and bed concrete 40 mm down size aggregates are, used. As Clinkerization process is an endothermic (heat absorbing) process it requires burning of Suitable fuel. The melded mass transforms into a nodular type of size 3 mm to 20 mm known as clinker. The clinker is taken from the clinker storage to cement ball plant containers for cement grinding. The increase in volume due to moisture content is known as the bulking of sand. Cement is the general term given to the powdered materials which initially have plastic flow when mixed with water or other liquid but has property of setting to a hard solid structure in several hours with varying degree of strength and bonding properties. Cement is a material which is used to bind other materials together. These drops strip off and fall on the floor. The hot gas and grinding materials factory outlet feeds to a separator which isolates fine and course items. The other raw materials that are utilized in cement manufacturing, called added substances, are high immaculate limestone, sand and iron minerals. Some of the main ingredients used to make cement include limestone, clay, shale, iron, and sand. OPC: 33 grade, 43 grade and 53 grade (OPC), Sand, gravel, crushed stones which are the products of weathering or crushing of rocks are known. Storage of cement: Cement absorbs moisture from air and hydrates, which results into loss of strength. In the wet process, the drying process is fuel utilization. Iron. Since a form of calcium carbonate, usually limestone, is the predominant raw material, most plants are situated near a limestone quarry or receive this material from a source via inexpensive transportation. by mixing argillaceous and calcareous materials in suitable proportions and burning at a temperature of. These days many cement processing plants utilize present day creation innovation to expand the limit and nature of cement. Here I have explained the types of cement manufacturing process in detail so that you can understand all the minor and major details about the cement manufacturing process. CEMENT MANUFACTURING PROCESS ! I am additionally revealing to you that an all around evaluated cement likewise improves the quality of cement. Wet process cement manufacturing method can be used to produce various types of Portland cement, such as ordinary Portland cement, white Portland cement, oil well cement, etc. Note that the quality properties of cement are impressively affected by the cooling pace of the clinker. The slurry on being showered against a hot surface of an adaptable chain loses dampness and becomes pieces. Alkalies, if in excess, cause, ordinary portland cement contains the following chemical compounds, 4. The size and shape, of gains may be felt by touching it with fingers. Applications of Wet Process Cement Manufacturing. IS code classifies sand as a grading zone. Afterward, the dry process is widely used, in light of the modem improvement of the procedure of dry blending of powdered materials utilizing packed air. Tetracalcium alumino ferrite. The pivot of the rotating oven makes the chips move from the upper end towards the lower end of the furnace exposing itself to increasingly elevated temperatures. Dry process 2. The fine materials called preheater dust or electrostatic separator dust are gathered from channels and taken care of into screw transports and are then blended in with the fine material in an air slide and shipped to an airdrop vessel through an air slide. In the dry and semi-dry process the raw materials are squashed in a dry state. argillaceous material (clay) and then grinding, types of cement. Typically for the manufacturing of cement, the fuels utilized are powdered coal, oil or petroleum gas. Evaporation of free water 2. Cement manufacturing process and its selection with the help of this post. The hot gas and fine materials enter a multistage “tornado” to isolate fine materials and gases. It subdivides the cement paste into thin films and allows it to spread and adhere. Manufacturing Process of Cement: • Quarry • Grinding • Burning • Grinding • Storage • Packing • Dispatch heavy cylinder of 2.5 to 3.0 m in diameter and 9 to 12 m in length. The hot gases originating from a (preheater/oven framework) enter the plant and are utilized in raw factories for drying. Other raw materials are utilized to control the oven feed blend configuration, in particular sand, and iron metal. Wherever possible, we tend to give reasons as to why a particular cement type is more suitable for a given purpose than other types. Cement Manufacturing Process. Cement Manufacturing Process. Over the years, cement in Malaysia has further developed thanks to technology. Sulphur makes cement unsound. Methods of cement manufacturing 1- Wet process ___ grinding and mixing of the raw materials in the existence of water. The most recent Technology with a cutting edge control framework incorporates stacker and reclaimer, on-line X-beam analyzer, Fuzzy Logic oven, and different process control. The first step of Cement manufacturing process is to quarry the principal … percentage of weight retained on the above sieves divided by 100 gives fineness modulus (FM). • Dry Process - 74% of cement produced. The preheater-furnace framework comprises of a multi-stage twister. Here, beneath you can peruse both the “wet” and “Dry” process in detail. It prevents shrinkage and adds. P ortland cement is by far the most common type of cement in general use around the world. Manufacture of cement - consists of mixing, burning, and grinding processes. The last mentioned, called reject, is shipped off the plant channel by means of an air slide for regrinding. 2- Dry process ___ grinding and mixing of the raw materials in their dry state. TYPES OF CEMENT Ordinary Portland cement (OPC) contains lime (60 – 67%), silica (17 – 25%), alumina (3 – 8%) iron oxide (0.5 – 5.0%), calcium sulphate (3 – 4%), magnesia (0.1 – 3.0%), sulphur oxide (1 – 3%) and alkalies (0.4 – 1.3%). Clinker and gypsum for OPC, limestone for limestone cement, and slang for slag cement are totally separated from their individual containers and taken care of to the cement factories. To meet the requirements of special situations, the following types of concrete are manufactured: To measure the workability slump test, compaction factor test or Vee-Bee consistometer tests are. TYPES OF CEMENT, oxide (0.5 – 5.0%), calcium sulphate (3 – 4%), magnesia (0.1 – 3.0%), sulphur oxide (1 – 3%) and, alkalies (0.4 – 1.3%). That homogeneous remedied slurry is applied by a spout shower on the upper finish of the rotating oven. Lime imparts strength. Silica contributes to strength by forming dicalcium and, Excess silica prolongs setting lime. With a little change in the above process, we have the semi-dry process likewise where the raw materials are ground dry and afterward blended in with around 10-14 percent water and further consumed to clinkering temperature. It fills the gap between building blocks and gives a level surface to mortar. This is accomplished for the simple trade of warmth via wind current during the further substance response. After about 20% moisture content, thin films start breaking and volume reduction takes, The field tests are possible to find the presence of clay, salt, and organic impurities. works like flooring roofing and columns 20 mm down size aggregates are. Hot clinker release from the furnace drops onto the mesh cooler for cooling from around 1350-1450 C to roughly 120 C. In the cooler, the amount of cooling air needed for clinker cooling is extricated from the air by various cooling fans and took care of into the cooler chambers and pressurized through the cooler plate and clinker bed. At that point, the mixed supper is sieved and applied to the process in a pivoting plate called granulator. Remember almost 40 % of the total cost spent for manufacturing cement is for fuel and power. Table shows the raw materials for Portland cement manufacture The mixing procedure of the manufacture of cement is done in 2 methods, 1. 4. on the basis of the percentage of sand passing. Cement removed from storehouses is passed on to the programmed electronic packers where it is pressed in 50 kg sacks and dispatched in trucks. HOW TO GET CIVIL ENGINEER LICENSE IN INDIA 2020? The hot gases with fine materials enter an electrostatic precipitator to isolate the fine materials from gases. Reaction of CaO with silica to form dicalciu… curing is not satisfactory shrinkage cracks may develop and durability is reduced. Common materials used to manufacture cement include limestone, shells, and chalk or marl combined with shale, clay, slate, blast furnace slag, silica sand, and iron ore. Following is the procedure of manufacturing cement by dry process using modern technology: Boulders of limestone upto 1.2m size are transported in huge dumpers upto 300kN capacity and dumped into the hopper of the crusher. The raw blend, high evaluation limestone, sand, and iron metal are taken care of from their containers to raw factories, called air cleared plants, for drying and fine grinding. For thin members, 12.5 mm sized aggregates are used. One of the fascinating focuses about cement is that the quality properties of cement rely on the cooling pace of the clinker, in light of the fact that the pace of cooling impacts the level of crystallization, the size of the precious stone and the quantity of shapeless materials present in the clinker. At that point in the ball or cylinder plant, it is blended in with mud or shale with water to frame a slurry. Here, clinker is produced from the raw mix through a series of chemical reactions between calcium and silicon dioxide compounds. INTERNAL AND EXTERNAL PLASTERING WORK PROCEDURE - TYPES, CHECKLIST, PLINTH BEAM WORK PROCEDURE - BUILDING, CHECKLIST, PROTECTION. For the avoidance of blaze setting of the cement 3 to 5 % of gypsum is added. To determine fineness modulus sieves to be used are. Wet process is one of the first types of cement manufacturing process. Though the process is complex, the events of the clinker production can be written in the following sequence: 1. Almost around one hour of air circulation, a uniform combination is acquired, that circulated air through force will in general act like a fluid. Cement clinker is made by preprocessing of furnace feed into the preheater-oven framework. A piece of the hot air extricated from the cooler is used as an auxiliary and tertiary air for ignition in a rotating oven and burning chamber, individually. Step 1: Mining. At present Portland Cement is manufactured by two processes, Dry Process, and Wet Process. This is the place where the oxides in raw materials will be consolidated to shape mixes in the clinker. The slurry is a fluid of rich consistency with a water substance of around 35 to 50 percent, wherein particles, squashed to the fineness are held in suspension. The plant release is taken care of to a pail lift which takes the material to a separator which isolates fine and coarse items. preferred. The last is shipped off the plant gulf for regrinding and the eventual outcome is put away in solid storehouses. At that point it is moved by trucks and emptied into the container of a mud smasher. At that point, cooled clinker ground in a ball plant. From that point forward, in the last stockpiling tanks by the fomentation of slurry, it is kept inhomogeneous condition. TYPES OF CEMENT, FLOW CHART. To find the strength, compression tests are conducted on 150 × 150 × 150 mm cubes after 28 days. to the density of mortar. The sand and iron minerals are transported from outside the plant (from various providers) by trucks and emptied into open yard heaps, called sand and iron metal heaps. It is kept slightly inclined to the, horizontal and can rotate at 15–20 revolutions per minute. some admixtures are added to introduce special properties. Curing should be done well in the first 2 weeks and continued for another 1–2 weeks. The ball plant pounds the feed to a fine powder in two chambers, specifically the first and second chambers. standard sand with specified water should give the strength as shown in Table. MIX DESIGN CONCRETE PROCEDURE AS PER IS CODE, GRADES OF CONCRETE, ADVANTAGES, RATIO, READY MIXED CONCRETE PROCEDURE - ADVANTAGES, TYPES, RMC, PLANT, DISADVANTAGES, REINFORCED CEMENT CONCRETE - TYPES, USES, ADVANTAGES, RCC, MATERIAL, CHECKLIST, DESIGN, CEMENT MANUFACTURING PROCESS! These repellents form a film around the materials of the concrete and produce a water-repelling mix. The raw blend is taken care of into a roundabout storage unit called a raw blend storage. The properties of this formless material for comparative synthetic creation will be not the same as the one which is solidified. The major raw materials used in the manufacture of cement are Calcium, Silicon, Iron and Aluminum. of grinding about 3 to 4 percent of gypsum is added. cement. as aggregates. Cement Manufacturing Process Phase 1: Raw Material Extraction Cement uses raw materials that cover calcium, silicon, iron and aluminum. In this post, we are going to discuss the different types of cement and its uses. Today we are going to start here one very important topic i.e. Calcination of the calcium carbonate (CaCO3) to calcium oxide (CaO) 4. The raw plant contains two chambers, isolated by stomach, specifically a drying chamber and a grinding chamber. cement manufacturing process ! temperature at the feed end is 1400°C to 1500°C. In the mature age, as a result of the chance of more exact control in the blending of raw materials, the wet process is famous. The cement manufacturing process involves several key steps, including preparing the raw materials, grinding the materials together, heating the newly formed clinker in a kiln, and finishing the cement with fine grinding. The liter load of the clinker demonstrates the nature of the clinker. As a whole Civil Engineer realizes that for the development of good cement a decent evaluation of total is required, acceptable reviewing cement particles are additionally needed for good concrete. The limestone is squashed in the primary smasher called a jaw smasher and then taken care of into the subsequent smasher called an effect smasher with blending of muds to lessen molecule size beneath 50mm. The cylinder is provided with steel, and length 90 to 120 m, placed at an inclination 1 in 25 to 1 in 30. The high immaculateness limestone is squashed in a solitary jaw smasher and then squashed more in an optional smasher to diminish the size to totally go through a 50mm strainer. Limestone is for calcium. The released raw blend (limestone 70%, dirts 30%) is taken care of onto a belt transport and passed over a mass material analyzer. In the construction industry, there are different types of cement. Laboratory tests may be conducted to ascertain. 10 mm, 4.75 mm, 2.36 mm, 1.18 mm, 600 microns, 300 micron, and 150 microns. Also, particles are isolated via air flows and taken to capacity. Physical requirements of ordinary portland cement are: specific surface, it should not be less than 2250 cm2. An amount of water around 12 percent by weight is added to make the mixed feast into pellets. The two chambers have a specific amount of ball charge of various sizes from 17mm to 90 mm. Coal dust is injected from the lower end and the mix is fed from the top end. The word "cement" can be traced back to the Ancient Roman term opus caementicium, used to describe masonry resembling modern concrete that was made from crushed rock with burnt lime as binder. First- in-first-out rule should, The drainage system on the roof and around the storage should be, 1. 1400°C to 1450°C to get clinkers, which are then ground to get cement. Along with these main types, depending on the composition and characteristics there are many types of cement. The. At that point, they are processed in a pounding factory, dried and decreased to fine powder-like. Quick Setting Cement: These Types of Cement are quite different than rapid hardening cement.. Its quality is that it set into a stone-like mass within a period of fewer than 30 minutes. The main difference between these two methods of manufacturing of cement is that in the dry process, calcareous and argillaceous raw materials are fed into the burning kilns in a perfectly dry state. The best variety of natural cement is known as Roman cement. More than 30 raw materials are known to be used in the manufacture of portland cement, and these Wet Process (The rotary kiln is an essential and important component of a cement manufacturing factory. • Wet process high fuel requirements - fuel needed to evaporate 30+% slurry water. The fuel is utilized to give the warmth needed to change over the oven feed into clinker. Sources of fine aggregates on the basis of which sand is classified are: sea sand, river sand, stream sand, pit sand and manufactured sand. Hydrophobic cement is made by grinding Ordinary Portland Cement clinkers, gypsum, and water-repelling substances like stearic acid and oleic acid in the manufacturing process itself. The fundamental wellspring of warmth is gaseous petrol. Cements are mainly of two types. preheater with five phases, ignition chamber, riser channel, turning oven, and mesh cooler. The grinding chamber contains a specific amount of ball charge in an alternate size going from 30mm to 90mm. The particles are squashed into the necessary fineness level. Types of cement : Followings are the 19 types of cement: Ordinary Portland cement ; Portland pozzolana cement Lime, silica, and alumina get recombined. For normal R.C.C. They are three types of mud utilized in cement manufacturing, to be specific silty mud, Zafarana mud, and Kaolin. The calcareous component can be limestone, chalk, marine shells, marl whereas argillaceous … possible, in any case, not more than 0.8 m. compacting or by using vibrators. • C2S hydrates slowly and increases strength over a year and contributes to ultimate strength. Methods of Manufacturing Process of Cement. Raw meal separated from the storehouse, presently called oven feed, is taken care of to the highest point of the preheater by means of a transport called the Poldos for pyro-processing. determined carefully since the workability of concrete increases with the quantity of water but the strength. The important properties of hardened concrete are: code classifies concrete mix as M 20, M 25, etc. Types of Cement Manufacturing Processes • Wet Process • Dry Process 19. The mixed feast is changed over into pellets by the expansion of water around 12 percent by weight. The cooled clinker releases from the cooler into the container transport and it is moved to the clinker storage. Most of the raw materials used are extracted from the earth through mining and quarrying and can be divided into the following groups: lime (calcareous), silica (siliceous), alumina (argillaceous), and iron (feurriferous). The required quantity of. More modest types of hardware are utilized in dry process similar to wet process and dry process is additionally affordable. The strategies of the cozy blending of raw materials in powder structure were not accessible at that point. If. 16. Ball plant is a solidified steel ball that has various chambers that are charged in arrangement forward. The raw materials are crushed and grinded into small suitable size particles in the first step of the manufacture of cement and there are three types of the manufacturing process; Dry Process; Wet Process; Semi Wet Process. It rotates at a rate of 1 to 3, rotation per minute. For small works nominal mixes as shown is Table may be used. Magnesia provides hardness and colour. As the materials proceed at that point, the material moves down to the lower end of the turning furnace, the dry material goes through a progression of substance responses until at long last, in the most sweltering piece of the oven, where the temperature is in the request for 1500°C, around 20 to 30 percent of the materials get melded. At long last, the limestone is extricated dynamically from the reserve by reclaimer and passed on to a raw plant receptacle, called the limestone container, for grinding. Stage 2: Crushing, stacking, and reclaiming of raw materials, Stage 3: Raw meal drying, grinding, and homogenization. Process of Manufacturing of Cement The cement is manufactured by integrating the calcareous component and argillaceous component in a ratio of 3:1. The differences between each type of cement are its properties, uses and composition materials used during the manufacturing process. This about the manufacturing of cement. concrete. We will understand the various terminologies and engineering concepts used in cement technology with the help of this category. TYPES OF CEMENT. 4CaO◊ Al2O3 Fe2O3, It also contains small quantities of impurities like calcium oxide (CaO) and magnesium oxide, • C3A is first to react and sets generating heat. Although the process for cement manufacture is relatively similar across North America and much of the globe, the reference to cement specifications can be different depending on the jurisdiction. In the wet process, above all else, the recently quarried limestone is squashed into more modest pieces. These minerals are used in different form as per the availability of the minerals. The kiln phase is the principal stage of the cement production process. The hammer mill crushers of … Turning furnace is a 3m to 8m distance across steel chamber, fixed with imperviousness to fire recalcitrant materials, fitted on roller orientation and equipped for pivoting about its own personal hub at a planned speed. Types of Cement Processes • Wet Process. Followings are the other cement types: Ordinary … The pace of cooling impacts the level of crystallization, the size of the precious stone and the quantity of shapeless materials present in the clinker. • C3S hardens early and develops strength in the first 28 days. The ball mill or tube mill contains steel balls. Be not the same as the bulking of sand process and its uses or... Should not be less than 2250 cm2 the first and second chambers classifies concrete mix as m,! Fuel is utilized to control the oven feed into the preheater-oven framework given! A level surface to mortar second chambers raw blend is taken care of into a nodular type of 3! 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