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Protection
Corrosion

Handbook
1
Corrosion Protection Handbook
Version 1.80 - May 2015

Copyright © 2015 AiAX Italia Srl

Via T.Boccuccia, 18 - 00033 Cave (RM) Italy
T +39 06 95308103
F +39 06 95000142
E info@aiaxcoatings.com
www.aiaxcoatings.com
VAT N. 01683461006

The information contained in this document represent a simple indication and have been
elaborated, starting from specific experiences that AiAX Italia Srl, did with different
customers and applications. Expressing sometimes the results of specific case studies,
AiAX Italia Srl can not be considered responsible for any error resulting from direct or
indirect use of this document and the information contained in it.
The reproduction of this document, in part, in total or for simple internal use of any
means, device, unless previously authorized in writing by AiAX Italia Srl, is not allowed.
The information contained in this document, in the view of the continuous improvement,
are subject to change; therefore, simple and/or substantial changes are possible without
prior notice.
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INDEX
Introduction

Corrosion in HVAC systems

Corrosion protection

The anticorrosion flooding process

Application case study

Information about AiAX Italia

AiAX Coatings Products

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Introduction
In over 30 years of activities in the HVAC&R market we have accumulated a
certain experience and noted the importance of preservation of energy
efficiency during the life cycle of installations.

Many are the factors influencing the efficiency of an HVAC&R system: in

short we can say that we go from the initial selection of the most
appropriated system for the specific application to a correct use of the
installed units and finally to good maintenance practices.
In moving forward our mission of corrosion protection of finned pack heat
exchangers of various HVAC&R pieces of equipment all over the world, we
have realized that the subject is not of easy interpretation and valutation;
therefore we have deemed it useful to publish this “Corrosion Protection
Handbook” to make available our experience to all those interested to the
corrosion problems.

The present document contains theory and practical cases derived from our
research and development sector in cooperation with some of the primary
European manufacturers of high efficiency chillers and rooftops.
We do not pretend to have treated the subject in an exhaustive way but we
feel sure that the achieved results can be of interest to the market operators
more sensible to the corrosion subject on HVAC&R equipment and to the
dangers that follow in terms of reliability and energy efficiency during the
system life cycle.

Good reading !

Gianni Di Pietro
Founder and Managing Director
of AiAX Italia Srl
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Corrosion in
HVAC systems
Definition of corrosion

Let us start with a definition of a finned pack heat exchanger commonly called a coil. In its basic version it
is formed by a round copper tube and an aluminium fin.
The coil is an important component of units like water chillers, aircooled condensers, dry coolers and from
its performance depends most of the energy consumption of a cooling system.
In the coils the primary fluid running in the tubes can be: water , refrigerant or steam while the secondary
fluid going through the fins is invariably air.
Let us now give a definition of corrosion: it is a process which leads to the alteration or
destruction of a metal. Metals are notoriously subject to corrosion and particularly from atmospheric
agents. The two most common forms of corrosion are known as:
- galvanic corrosion
- corrosion from atmospheric impact

Galvanic corrosion
When two dissimilar metals are electrically connected in the presence of an
electrolyte a reaction starts leading to the disappearance of the less noble
metal. In the case of a coil it is the aluminium, less noble than copper, that
will be corroded.

Corrosion from atmospheric impact

We call in this way the corrosion created by a reaction with the environment.
As said before the secondary fluid of a coil is always air. Unfortunately air is
almost never pure and uncontaminate. In fact, very often, air contains
elements which are highly corrosive for copper and aluminium.
Some examples of environments with polluted air:

1 Industrial ambients

2 Urban ambients

3 Rural ambients

4 Marine ambients
Outdoor ambient air can include
elements that can generate
corrosion to the exchangers
generally used in HVAC Units.
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1 Industrial ambients
The industrial areas are almost always associated with emission in the atmosphere of various pollutants
like sulphur and nitrogen oxides. The combustion of solid fuels releases sulphur oxides (SO2, SO3) and
nitrogen oxides (NOx). These gases accumulate in the atmosphere and return to the ground as acid rains
or low pH dews (acid dews). In an industrial atmosphere there are normally also particles of metallic
oxides, chlorides, sulphates, sulphuric acid, carbon and carbon compounds. These particles in the
presence of oxygen, water or high humidity can be extremely corrosive.

2 Urban ambients
Densely populated areas are always associated with emissions in the atmosphere of car discharge gases
and, during the heating periods, of high contents of combustion products. Both conditions increase the
concentration of sulphur and nitrogen oxides.

3 Rural ambients
The rural ambients can contain high levels of ammonia deriving from fertilizer and animal drop-outs.

4 Marine ambients
5
Coastal areas in the proximity of the sea are characterized by an abundance of sodium chloride (salt)
which is transported by spray, fogs and mist. The saline atmosphere induces per se corrosion but, most of
all, acts as a catalyzer of corrosion in the presence of industrial emissions. A marine-industrial
environment is probably the worst situation from the corrosion point of view.

Main effects of coil corrosion: loss of efficiency

and increase of energy consumption
A coil is fundamentally a heat exchanger and heat is transferred through the
tube surface to the fin. The fin is in close contact with the tube which is, in
fact, expanded into the fin collar. The first effect of pollution on the fin is a
deposit of dirt on it, partially isolating the secondary heat exchange surface
from contact with the air. Further on, when the dirt particles have been in
contact for a sufficiently long time and the corrosion process is started,
(corrosion from atmospheric impact),the finned surface starts to
deteriorate, decreasing the heat exchange capacity. One should not forget
that the fin thickness is of the order of magnitude of 0.17 mm. and the
corrosion does not take too long a time to eat up such a low thickness.

In the same time the galvanic corrosion, that appears at the bimetallic
contact between copper and aluminium, erodes the collar eliminating the
close contact between tube and fin. Decreasing the heat exchange even Effects of corrosion on a
more. typical air side Copper-
The disappearance of the collar exposes the tube; some crystals can be Aluminium exchanger,
installed on a unit located in a
deposited and this can lead to a pitting corrosion which provokes a leak of urban ambient, with high level
the primary fluid. If this is refrigerant, as it is for all condensing coils, it will of atmospheric pollution.
cause the stop of the unit, adding in the same time, additional pollution to
the atmosphere.
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Corrosion
Protection
The most common method of corrosion prevention is to coat the parts exposed to corrosion, avoiding the
contact with the polluting agents. This method can be applied also to coils, however we must keep in
mind some important points:

- the coils are heat exchangers. A coating acting as an insulating layer is

not appropriate;

- the fins have a special configuration which increases the air turbulence
thus improving the heat exchange, The coating must not modify the fin
configuration;

- the application of a layer of coat on both fin sides reduces the air
passage area. This generates a higher pressure drop which either reduces
the air flow or increases the absorbed power.

Example of a typical
Esempio di una batteria di
The above points have a vital importance and must be kept in mind when scambio termico a pacco
alettato protetta dalla
selecting the proper protection. There are however other protection features corrosione
which are convenient:

1 - good flexibility of the protection layer to follow the metal thermal

expansion/contraction;

2 - dirt repellence: the air passing through the fins deposits dirt which will
adhere less easily if the coating is particularly smooth;

3 - U.V. resistance : quite important for coils exposed to the sun;

4 - maintenance: the protection, however good its quality, will have a

resistance to athmospheric agents limited in time. It is advisable to re-apply
the product as soon as signs of deterioration appear. As we shall see some
coating methods do not allow re-applying the products;

5 - reduced cost of application: much as the method of application can

be technically advantageous it must be economically significant.
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The traditional solutions do not offer
the guarantees that Post-Coating can feature
In the market we have seen in the past several solutions to protect from corrosion but almost all had
weak points in one or another direction.

Use of different metals: a possible solution is to employ a coil with

copper tubes and copper fins. This surely eliminates the galvanic
corrosion. But copper is attacked by sulphur gases which are often present
in industrial ambients and not only there. The cost of the copper fin is, in any
case, quite high. An even more costly solution is the tinning of the copper
fin. If made by dipping the cost is really prohibitive. If obtained by using a
pre-tinned coil it will have no effectiveness as the cuts deriving from the fin
press moulding will uncover the underlying metal which is no longer
protected.

Surface coating: the basic idea is to eliminate totally the contact between
the polluted air and the metal. We can distinguish two methods of
application of the coating:
Corrosion Effects on a
- Pre-coating typical Copper-Copper Coil
- Post-coating

Pre-coating: it is a layer of coat of few micron thickness applied on the aluminium coil before it enters the
fin press for the fin moulding. The process implies a great number of cuts on the fin edge, on the collar
and, if the fin is louvered, on thousands of louvers. The cuts eliminate the coating and expose the metal.
In reality this is NOT a protection against the corrosion.

Post-coating: it is a procedure in which the coating is applied after the

complete assembly of the coil. In this way the coating covers effectively all
the finned surface including the fin edges. Until the coat remains in place
there is no contact between metal and air. There is no doubt therefore that
the post-coating method is the correct answer to corrosion problems.

Post-Coating: a higher value

compared to Pre-Coating
Obviously the post-coating has a higher cost compared to pre-coating for Post-Coating: the complete
various reasons: solution for the corrosion
protection of the exchanger
a) transport costs, as the treatment is almost always carried out in a in all its parts.
factory different from that of the coil manufacturer;

b) packing costs, the coils must be protected for transport;

c) cost of the product which is of superior quality and is applied in higher

thickness than that of the pre-coating process.

So in the end the initial cost of a pre-coating can be sometimes less that a
post-Coating, on the other hand considering the long lasting value, including
better efficiency (due to possibility of re-application) post-coating, quite
often, offers a greater value for the customer than pre-coating.
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Different systems of Post-Coating
Having already shown that the only method that makes sense from the point of view of corrosion
protection is the post-coating one let us see which are the available methods:

1 by immersion

2 by spraying

3 by flooding

This first list of possible solutions must be immediately confronted with a fundamental and not to be
ignored element: the anticorrosion protection must be re-applicable.

The experience shows, in fact, that there is no method that can guarantee indefinitely in time against the
corrosion. It is always necessary a maintenance which keeps or reinstates the optimal resistance
conditions of a just applied treatment. We repeat what already mentioned: any non re-applicable method
has a time limited duration and should be considered an unvalid solution. The duration depends from
ambient conditions and can , in limit cases, be of only few months..

The immersion method is not re-applicable by definition. There are also limitations in the coil size
that can be treated as the immersion baths do not exceed 4-6 meters of length. The two other methods
(by spraying and by flooding) are re-applicable and are the only systems which can, according to our
experience, be considered safe from the point of view of corrosion protection.

THE ANTICORROSION PROTECTION

MUST BE RE-APPLICABLE
A good anticorrosion protection must consider two factors:

Penetration: it is necessary that the protection coating is total, i.e. that also the coil internal surface,
most difficult to reach, is coated. If a part of the surface is uncovered the corrosion can start in that point
and, once started, will expand under the coat layer. Leaving uncovered spots is equivalent to render
useless the whole treatment with waste of time and money.

Fin edge coverage: the most delicate point is surely the fin edge where the metal thickness is less than
200 micron and where, due to the limited surface support, it is higher the risk that the coating may not
adhere perfectly. Furthermore the fin edge, more exposed to the air flow, can be subject to erosion from
solid particles carried by the air.
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The anticorrosion
flooding process
AiAX COATINGS EXPERIENCES:
THE ANTICORROSION FLOODING PROCESS
Years of experience have convinced us that the absolute security of penetration of the protection in the
inner parts of the fin pack cannot be obtained only through a spraying procedure. In many cases the
penetration stops at few centimeters from each side of the coil and the quality of the result depends
substantially from the operator skill and attention.
For further protection of the fin edge, which we have noticed to be the critical point of the
coil, a second coating by spraying is superposed to that applied by flooding.
In this way the protection of the whole fin pack is guaranteed, while the re-applicability on the fin edge is
possible every time it becomes necessary.

Also on the side of the product, in parallel to our traditional products AiAX
Silver Flow that is a polyurethane based special coating applicable with a
flooding procedure and completely compatible with the AiAX Silver Spray
coating, also polyurethane based, and applicable with a spraying procedure,
we have introduced an innovation with the AA Aqua Aero which is water
based, very often used to protect Microchannel heat exchangers completely
in aluminium. These exchangers have a limited thickness, for this reason
they are normally protected with the spraying method.

The flooding method and the use of a water based product

represent a substantial progress in the state of the art of the
anticorrosion protections of coils.

ORIGIN OF THE ANTICORROSION

PROTECTION FLOODING PROCESS
The idea of coating by flooding was developed when the market demanded to protect the finned pack of
industrial coils with a pack thickness much higher than the standard normally used with condenser of
refrigeration units ( 3-4 rows maximum with a maximum thickness of around 120 mm). With a pack
thickness over 200 mm the traditional spraying method, in most cases, does not guarantee a good
penetration, whatever the nozzle pressure or the used procedure. The immersion method was the first
answer to the penetration problem from many suppliers (even if in certain cases, the complete
penetration is not guaranteed).

In any case the immersion method had and still has some disadvantages like:
-

The dimension of the bath in which the coil should be dipped is normally limited to only few
meters of length.
-

The quantity of chemical product to be used is far in excess of what adheres to the finned
surface. The product characteristics, in almost all cases, requires that the product is removed
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 from the bath when the application cycle is finished. This leads to substantial losses of
- products which increase the operation cost.

Many, if not all, the immersion products are not suitable also for spraying application. This
means that a touch up of the finned surface, sometime after the first application, is not
possible. The experience shows that, however good the product and the application method,
after a certain time (depending on installation site ambient conditions) a maintenance
intervention becomes necessary, particularly on the fin edge which, having a thickness of few
micron, is subject to lose the protection due to erosion or corrosion. A touch up intervention
on the fin edge, within a programmed maintenance, extends the life of a coil much beyond
the life of other components of the same unit. If the product is not re-applicable by spraying
and the touch up can be made only through another dipping process, it is quite evident that a
regular maintenance cannot be carried out: it would be necessary to remove the coil to send it
to the original applicator with clearly unbearable costs.

Exclusive flooding protection process

developed by AiAX Italia
The flooding system is the answer that eliminates all the disadvantages of the other methods. Let us see
the various steps:
-

The coil is positioned on an inclinable support

which can be moved from the horizontal to the
vertical position (90° rotation)
-

Any transportable coil length can be positioned

on the support which is open at the extremes
-

Under the coil is positioned a tank of width

and length sufficient to take all the products
percolating from the coil treatment. The tank has the
form of an inverted pyramid at the base of which a
container holds a sufficient quantity of product to
pour over the coil. The product is pushed by a pump
to the flooding outlet. In this way the quantity of
product into the container is reduced to the bare
minimum with a remarkable economic advantage.
-

The flooding outlet distributes the product

uniformly over the coil. The product goes through the
coil by gravity and the product not adhering to the
fins goes into the underlying tank. Thanks to the
gravity force the penetration of any thickness of coil
is guaranteed.

Once the flooding treatment is completed a further

coating is applied by spraying to protect the fin edge
which, as already mentioned , is the the part most
exposed to corrosion. In the same way it will be
possible to carry out maintenance interventions.
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Application case study
Chiller capacity: 329 kW
Energy efficiency is a focal point in designing new buildings and in retrofitting old ones. The condenser
coil of a chiller can lose part of its heat exchange capacity even in less than one year from the date of its
installation and the velocity of deterioration depends from the local environment.

A case history: chiller of 329 kW

cooling capacity. Estimation of
Efficiency decrease due to the
corrosion effect on condensing
air side exchangers.
In order to evaluate the impact on energy costs of
a chiller with untreated condenser coils we have
analysed the energy consumption in conditions of
average air pollution, typical of an urban
environment.

The data included in this example are the results of

studies made by our R&D department in
cooperation with some major european
manufacturers of high efficiency chillers and
rooftop units. We do not pretend to have treated
the subject in an exhaustive way but we feel sure
that the end results are of interest to the energy
conscious engineers.
The experience of the last fifteen years of direct
observation shows that the condensing
temperature of chillers increases in time with
respect to initial conditions.

Particularly we noted that, as an average, to every

degree °C of increase in the condensing
temperature corresponds an increase of electric
consumption of about 2% (consumption of the
compressors only).
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The above situation does not take into account maintenance interventions on the coils, which is a typical
case when the coils are not treated against corrosion and it is not required a specific maintenance in
order not to render nil and void the warranty.
Let us take, as an example, a chiller with four scroll compressors of about 329 kW of cooling capacity
(water 12-7°C and ambient air 35°C) with a compressor EER=3,17. The chiller is used in a comfort
installation. We shall have about 3.000 hours of yearly operation with a bell shaped load profile which, for
ease of understanding, we approximate as per the following table.

The yearly total of kWh 133.800 is referred to a brand new unit. Given the coil deterioration of Table 1 the
consumption will be:

In other words in the five years after the first year of operation there is an additional consumption of kWh
55.024 which at an average industrial cost of 0,17 €/kWh (Italy) yields a total of € 9.354.

To this cost, conservatively calculated, even if by broad outline, it should be added the longer time of
chiller operation to reach the desired temperature level. The above example would be even more
significant were the chiller operating in an industrial installation in which the yearly hours would be more
than 3.000 and with a more onerous load profile. Again as an order of magnitude we use the same
example in an industrial situation of process water cooling.

Due to the coil deterioration the consumptions will be those of Table 5.

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In other words in the first five years after the first year of operation there is an additional consumption of
kWh 148.049 which, at an average industrial cost of 0,17 €/kWh (Italy) yields a total of € 25.168.
It should be noted that we have assumed urban ambient conditions while in industrial areas conditions
are definitely worse.

Basically even class A units, after a certain period of time, depending on ambient conditions
of the site of operation, would decrease their performance without a proper anticorrosion
treatment in the condenser coil.

Pay-Back starting from the 2°/ 3° year

After the installation of the Chiller
As a cost index the application of an AiAX Coatings treatment on the coil of the example chiller would be
worth less than one third of the added cost of Table 5.The pay back period would be around 3 years for a
comfort installation and less than 2 years for an industrial application.

The application of an AIAX Coatings treatment reduces the risk of refrigerant leaks and of stopping the
chiller and ensures an optimal performance for the whole life cycle of the installation provided there is an
easy and low cost maintenance (periodical washing with water ad detergent).
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Information about
AiAX Italia
AiAX Coatings, more than 30 years of HVAC experience
Founded in 1978 from Gianni Di Pietro, AiAX Italia Srl has initially supplied services of engineering and
marketing in the Airconditioning and refrigeration markets. On the basis of the experience acquired in
years of activity in Midde and Far East and in Europe, the AiAX Coatings division has been created with
the intent of studying corrosion protection systems for finned pack heat exchangers, primary source of
energy dissipation in units like water chillers, condensing units, dry coolers and similar.
Recently the company has introduced new products of significant ecologic value and new application
procedures which project new light in the coil anticorrosion methods.
The new water based products (instead of solvent based) offer a protection certified by salt fog tests
while the flooding procedure guarantees a total coverage of finned packs of any commercial thickness. In
a period of macro-economic uncertainties the development of the Italian economy can only pass through
a reduction of the energy costs and an increase in the efficiency of equipment and production methods.
AiAX Coatings offers an important contribution making it possible the almost always unrealized wish of
maintaining the heat exchanger performance equal to that of the first day of operation for a prolonged
period of time.

Quality and safety certifications

AiAX Italia Srl certified ISO 9001

Quality is a central point in the products and services that AIAX Italia srl
offers to its customers and therefore an ISO 9001 certification has been
deemed a must.

AiAX Italia Srl certificata ISO 14001

The environment, together with the quality, is the other aspect to which AIAX
Italia srl has always given a high level of attention in order not only to offer
to its customers good products and services but also to contribute to the
environmental susteinability.
For this reason AIAX Italia srl has obtained the ISO 14001 certification.
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The traditional solvent based products
Designed for all types of finned coils with any thickness of the finned pack
- AiAX Silver Flow FL10K specific for flooding procedure
- AiAX Silver Spray KL10K specific for spraying procedure

The solvent based products, further improved, are used for the "Flooding
Method" coating which is in absolute the most performing procedure for
Round Tube Finned Pack coils.
The "Flooding Method" ensures penetration of the entire finned pack, and
then the protection is excellent both against galvanic corrosion and against
corrosion by accumulation of pollutant.
After the flooding of the entire finned pack it is normally don a further
finishing spraing application to cover the edge of the fins. Double protection
by "Flooding Method" and spray is the more serious approach so far
experienced for a consistent corrosion protection over time.
Ahestetic appearance
of the Protection
“AiAX Silver Flow FL10K” and
“AiAX Silver Spray KL10K”

Our innovative water based products

Particularly indicated for Microchannel Heat Exchangers
- AA Aqua Aero specific for spraying procedure
After about two years of tests we have optimized a water based anticorrosion
protection which represents a great progress in terms of facility of
application and of lack of solvent, often causing an unpleasant smell during
the application.
The curing times are also remarkably reduced. The new protection has the
same anticorrosion characteristics of the previous products and it is re-
applicable by spraying more than once, if necessary, for the maintenance of
Ahestetic appearance
the fin edge also directly on site. of the Protection
The previous solvent based products will be available for some time. The “AA Aqua Aero”
future is however reserved for water based products and therefore the
solvent based will be slowly phased out.
The colour of the new protection AA Aqua Aero is a light blue , different
from the silver colour of the solvent based products and definitely more
pleasant to look at.

The anticorrosion flooding process

We have set up a new application structure of the anticorrosion product by

flooding the coil, developed on the recent years experience.
The experience shows that in comparison with the traditional coating
systems available in the market, our flooding process guarantees a very
good protection of the finned pack of any commercial thickness.
The spraying process will be reserved to those cases where the flooding
method is not applicable for the geometry of the coil (frames and similar
cases) or for specific request of the customer.
With these characteristics, our process is suitable for being used for all
thickness of coils.

Our new innovative

flooding process,
suitable for being used
.

for all thickness of coils

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Products

AiAX Coatings has a complete range of anticorrosion protections specifically suitable for different HVAC
applications. The technical characteristics and the safety data of AiAX Coatings protections are
included in two different documents that can be downloaded from www.aiaxcoatings.com.

• AiAX Silver Flow FL10K - AiAX Silver Spray KL10K

Anticorrosion protection specific for finned pack heat exchangers.
Recommended for all thicknesses of the finned pack.
Application is possible both for ”Flooding Method” and spraying procedure.

• AA Aqua Aero
Anticorrosion protection specific for heat exchangers.
Particularly designed for Microchannel exchangers.
Application is possible with spraying procedure.

Free download of the above datasheet from internet: www.aiaxcoatings.com.

Other specifc AiAX Coatings products

available on demand
• PXX10K Panelcoat
Anticorrosion protection specifically studied to cover metal panels attacked by corrosion.It can be applied
over powder paint, on corroded surfaces and also on protection grilles.

• PXPP Pancoat
Anticorrosion protection specifically studied for the drain pans or the bottom panels of various units where
there is a concentration of polluting/oxidizing products.
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Notes
Corrosion Protection Handbook
Copyright © 2015 AiAX Italia Srl Distributed by:
Via T.Boccuccia, 18 - 00033 Cave (RM) Italy
T +39 06 95308103
F +39 06 95000142
E info@aiaxcoatings.com
www.aiaxcoatings.com
P.IVA 01683461006
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