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Unit 7, 142 Tennyson Memorial Avenue – Tennyson – Queensland – 4105
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SOURCE EMISSIONS MONITORING – BORAL WYEE
BORAL ROOFING NSW
Project ID. 10514
R_2
DATE OF RELEASE: 16/09/2016
Source Emissions Monitoring – Boral Wyee
Unit 7, 142 Tennyson Memorial Avenue – Tennyson – Queensland – 4105
AB
N: 8
7 6
04
85
1 0
78
Table 1: Document approval
Name Position Title Signature Date
Author David Arbuckle General Manager
16.09.2016
Reviewer Jeremy James Senior Consultant 12.09.2016
Approved Jeremy James Senior Consultant
12.09.2016
Table 2: Revision register
Revision Date Name Comment
R_0 18.08.2016 Aaron Dobson Initial release
R_1 12.09.2016 Aaron Dobson Updated PM10 results
R_2 16.09.2016 David Arbuckle Corrected Table 3 & 4 fluoride emission
rate calculationa
a Incorrectly reported as g/min instead of g/sec.
DISCLAIMER
Assured Monitoring Group acts in all professional matters as a faithful advisor to the Client and exercises all reasonable
skill and care in the provision of its professional services.
Reports are commissioned by and prepared for the exclusive use of the Client. They are subject to and issued in
accordance with the agreement between the Client and Assured Monitoring Group. Assured Monitoring Group is not
responsible for any liability and accepts no responsibility whatsoever arising from the misapplication or misinterpretation
by third parties of the contents of its reports.
Except where expressly stated, Assured Monitoring Group does not attempt to verify the accuracy, validity or
comprehensiveness of any information supplied to Assured Monitoring Group for its reports.
Reports cannot be copied or reproduced in whole or part for any purpose without the prior written agreement of Assured
Monitoring Group.
Where site inspections, testing or fieldwork have taken place, the report is based on the information made available by
the client or their nominees during the visit, visual observations and any subsequent discussions with regulatory
authorities. The validity and comprehensiveness of supplied information has not been independently verified and, for the
purposes of this report, it is assumed that the information provided to Assured Monitoring Group is both complete and
accurate. It is further assumed that normal activities were being undertaken at the site on the day of the site visit(s),
unless explicitly stated otherwise.
ACCREDITED FOR COMPLIANCE TO ISO/IEC 17025
The results of the tests, calibrations and/or measurements included in this document are traceable to
Australian/national standards.
Accreditation ID: 19703
Source Emissions Monitoring – Boral Wyee
Unit 7, 142 Tennyson Memorial Avenue – Tennyson – Queensland – 4105
AB
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EXECUTIVE SUMMARY
Assured Monitoring Group (AMG) conducted source emissions monitoring at the Boral Roofing
facility located at Wyee, NSW on the 19th & 20th July 2016.
A summary of results is presented below, for further details please refer to the body of this report. No
licence limit breaches were recorded.
Table 3: Summary of results – Kiln stack (EPA Point 4)
Release Point Parameter Unit of Measure Kiln stack - EPA Point 4 Licence
Limit
Date of testing dd-mm-yy 19/07/2016 -
Average exhaust Velocity m/sec 17 -
Average stack temperature °C 151 -
Moisture % 5.2 -
Dry standard stack flow rate Nm3/sec 7.8 -
Total solid particulates mg/Nm3 24 250
emission rate g/sec 0.19 -
PM10 mg/Nm3 6.8 -
emission rate g/sec 0.053 -
Sulphur dioxide mg/Nm3 29 -
emission rate g/sec 0.23 -
Sulphur trioxide (as H2SO4) mg/Nm3 6.7 -
emission rate g/sec 0.053 -
Carbon monoxide mg/Nm3 33 -
emission rate g/sec 0.25 -
Oxides of nitrogen (NO2) g/Nm3 0.055 2.5
emission rate g/sec 0.43 -
Total Fluorides mg/Nm3 10 50
emission rate g/sec 0.079 -
Table 4: Summary of results – Dryer stack (EPA Point 6)
Release Point Parameter Unit of Measure Dryer Stack - EPA Point 6 (VE2)
Licence Limit
Date of testing dd-mm-yy 20/07/2016 -
Average exhaust Velocity m/sec 6.0 -
Average stack temperature °C 32 -
Moisture % 4.9 -
Dry standard stack flow rate Nm3/sec 0.48 -
Total solid particulates mg/Nm3 0.74 -
emission rate g/sec 0.0029 -
PM10 mg/Nm3 < 0.74 -
emission rate g/sec < 0.0029 -
Sulphur dioxide mg/Nm3 0.76 -
emission rate g/sec 0.0029 -
Sulphur trioxide (as H2SO4) mg/Nm3 0.14 -
emission rate g/sec 0.00055 -
Carbon monoxide mg/Nm3 1.8 -
emission rate g/sec 0.0070 -
Oxides of nitrogen (NO2) g/Nm3 < 0.0021 -
emission rate g/sec < 0.0080 -
Total Fluorides mg/Nm3 < 0.71 -
emission rate g/sec < 0.0018 -
Source Emissions Monitoring – Boral Wyee
Unit 7, 142 Tennyson Memorial Avenue – Tennyson – Queensland – 4105
AB
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TABLE OF CONTENTS
1 INTRODUCTION ....................................................................................................................................................... 5
2 METHODOLGY & EQUIPMENT ............................................................................................................................ 6
2.1 SAMPLING METHODOLOGY ........................................................................................................................................................ 6
2.2 SAMPLE LOCATION ....................................................................................................................................................................... 7
2.3 PLANT OPERATIONAL DATA ....................................................................................................................................................... 8
2.4 TEST EQUIPMENT ............................................................................................................................................................................ 9
3 QUALITY ASSURANCE & QUALITY CONTROL (QA/QC) ....................................................................... 10
4 DEFINITIONS ............................................................................................................................................................. 11
5 RESULTS .................................................................................................................................................................... 12
LIST OF TABLES
TABLE 1: DOCUMENT APPROVAL .................................................................................................................................................................... II
TABLE 2: REVISION REGISTER ........................................................................................................................................................................... II
TABLE 3: SUMMARY OF RESULTS – KILN STACK (EPA POINT 4).................................................................................................... III
TABLE 4: SUMMARY OF RESULTS – DRYER STACK (EPA POINT 6) ............................................................................................... III
TABLE 5: SAMPLING SCHEDULE ...................................................................................................................................................................... 5
TABLE 6: TEST METHODS ................................................................................................................................................................................... 6
TABLE 7: SAMPLING NOTES .............................................................................................................................................................................. 6
TABLE 8: ANALYSIS NOTES ............................................................................................................................................................................... 6
TABLE 9: SAMPLE LOCATION SUMMARY .................................................................................................................................................... 8
TABLE 10: PRODUCTION DETAILS .................................................................................................................................................................. 8
TABLE 11: SAMPLING DATA QA/QC CHECKLIST ...................................................................................................................................10
TABLE 12: LABORATORY DATA QA/QC CHECKLIST ............................................................................................................................10
TABLE 13: DEFINITIONS ....................................................................................................................................................................................... 11
TABLE 14: TEST RESULTS – KILN STACK MANUAL SAMPLES ............................................................................................................ 12
TABLE 15: TEST RESULTS – KILN STACK GASES ..................................................................................................................................... 13
TABLE 16: TEST RESULTS – DRYER STACK MANUAL SAMPLES ........................................................................................................ 14
TABLE 17: TEST RESULTS – DRYER STACK GASES ................................................................................................................................. 15
LIST OF FIGURES
FIGURE 1: KILN STACK RELEASE POINT (LEFT) AND DRYER STACK RELEASE POINT (RIGHT) ................................................... 7
FIGURE 2: BORAL WYEE SITE LOCATION ..................................................................................................................................................... 7
FIGURE 3: FULL ISOKINETIC SAMPLING ASSEMBLY ................................................................................................................................. 9
FIGURE 4: KILN STACK GAS TRENDS ............................................................................................................................................................ 16
Source Emissions Monitoring – Boral Wyee
Unit 7, 142 Tennyson Memorial Avenue – Tennyson – Queensland – 4105
AB
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1 INTRODUCTION
Assured Monitoring Group (AMG) was appointed by Boral Roofing NSW to sample and analyse
source emissions from the Wyee facility. The sources sampled included a kiln stack emission point
and dryer release point. Sampling was conducted by AMG on the 19th & 20th July 2016 during typical
site operations.
AMG was responsible for the collection and analysis of samples, unless otherwise indicated. The
samples were recovered and stored in the appropriate manner until their return to the laboratory
where the samples were prepared and analysed according to the methodologies listed below in this
report.
This test program was conducted to satisfy the conditions detailed in the Environment Protection
Licence (number 2702 – 11 May 2011) issued to Boral Montoro Pty Limited for their facility located at
Toomey’s Road East, Bushels Ridge. The table below details the sampling program as conducted on
this occasion.
Table 5: Sampling schedule
Parameter Kiln stack - EPA Point 4 Dryer Stack - EPA Point 6
Particulate matter – total 1 1
Sulphur dioxide – SO2 1 1
Oxides of nitrogen (as NO2) 2 2
Sulphuric acid mist – SO3 1 1
Fluoride - total 1 1
Particulate matter – PM10 1 1b
b PM10 is reported assuming 100% of total solid particulates are present as PM10
Source Emissions Monitoring – Boral Wyee
Unit 7, 142 Tennyson Memorial Avenue – Tennyson – Queensland – 4105
AB
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2 METHODOLGY & EQUIPMENT
2.1 Sampling methodology
All sampling and analysis was carried in accordance to the listed requirements in Table 6. Any
specific method comments have been documented where required.
Table 6: Test methods
Parameter Reference
Test Method NSW EPA TM Notes Analysis
Sample plane criteria AS4323.1 TM-1 A 1
Flow rate, temperature and
velocity USEPA Method 2 TM-2 nil 1
Stack gas molecular weight USEPA Method 3 TM-23 B 1
Oxygen (O2) USEPA Method 3A TM-25 B 1
Carbon dioxide (CO2) USEPA Method 3A TM-24 B 1
Moisture content USEPA Method 4 TM-22 nil 1
Total solid particulates AS4323.2 TM-15 nil 1
Sulphur dioxide – SO2 USEPA Method 6 TM-4 nil 1
Oxides of nitrogen (as NO2) USEPA Method 7E TM-11 B 1
Sulfuric acid mist – SO3 USEPA Method 8 TM-3 nil 1
Fluoride – total USEPA Method 13B TM-9 nil 2
Particulate matter – PM10 USEPA Method 201A OM-5 nil 3
Table 7: Sampling notes
Note Comment
A
Sample location on the dryer release point is compliant but non-ideal as per AS4323.1. The sample location is greater than two, but less than six diameters downstream from a disturbance. The temperature and velocity survey showed that the sample position was in compliance to items (a) to (f) as per AS4323.1.
B Analyser calibration pre and post field work in our laboratory.
Table 8: Analysis notes
Note Company Work performed NATA ID Report Number
1 Assured Monitoring Group Sampling & analysis 19703 10514
2 EnviroLab Services Fluoride analysis 2901 150669
3 Particulate & surface sciences Analysisc - 10514-2-3
c A particulate sample was collected isokinetically from the stack, with the particulate catch them being
analysed by particle counting instruments for determination of particle size distribution. The percentage of particles less than 10μm in size was then applied to the total particle matter result to determine the PM10
fraction of the total catch.
Source Emissions Monitoring – Boral Wyee
Unit 7, 142 Tennyson Memorial Avenue – Tennyson – Queensland – 4105
AB
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2.2 Sample Location
The figures below show the site and sample location.
Figure 1: Kiln stack release point (left) and dryer stack release point (right)
Figure 2: Boral Wyee site location
Source Emissions Monitoring – Boral Wyee
Unit 7, 142 Tennyson Memorial Avenue – Tennyson – Queensland – 4105
AB
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Table 9: Sample location summary
Sample location Kiln Stack Dryer Stack
Stack Shape CIRCULAR CIRCULAR
Stack Diameter (m) 0.97 0.89
Stack Cross Section Area (m2) 0.74 0.62
Distance to upstream disturbance (m) 9.6 2.8
Diameters (D) 9.9 3.1
Distance to downstream disturbance (m) 2.4 4.0
Diameters (D) 2.5 4.5
Total traverse point factors 1 , 1 , 1 , 12 1.1 , 1 , 1.1 , 16
Port size (mm) 100 100
Port Thread Type BSP BSP
Number of traverses 2 2
Number of points per traverse 6 8
Total number of traverse points 12 16
Flow & temperature compliance check YES YES
2.3 Plant operational data
The table below summarises the plant operation data at the time of sampling.
Table 10: Production details
Item
Cars per shift 35
Tiles per shift 33, 600
Source Emissions Monitoring – Boral Wyee
Unit 7, 142 Tennyson Memorial Avenue – Tennyson – Queensland – 4105
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2.4 Test equipment
The sampling equipment was transported to site and specifically setup at the test location. Sampling
was performed using one complete isokinetic sampling train with an out-of-stack heated filter.
All equipment used during the course of the testing is sourced from Apex Instruments, an industry
leader in the supply of source testing equipment.
Figure 3: Full isokinetic sampling assembly
Source Emissions Monitoring – Boral Wyee
Unit 7, 142 Tennyson Memorial Avenue – Tennyson – Queensland – 4105
AB
N: 8
7 6
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3 QUALITY ASSURANCE & QUALITY CONTROL (QA/QC)
AMG operates within a quality system based upon the requirements of ISO17025. Our quality system
defines specific procedures and methodologies to ensure any project undertaken by AMG is
conducted with the highest level of quality given the specific confines of each project. The overall
objective of our QA/QC procedures is to representatively sample and accurately analyse
components in the gas streams and therefore report valid measurements of emission concentrations.
To ensure representativeness of field work, our quality procedures target:
1. Correct sampling locations
2. Sample time
3. Frequency of samples and
4. Method selection & adherence
To ensure representativeness of lab work, our quality procedures target:
1. Sample preservation
2. Chain of custody (COC)
3. Sample preparation and
4. Analytical techniques
AMG maintains strict quality assurance throughout all its sampling programs, covering on-site ‘field
work’ and the analytical phase of our projects. Our QA program covers the calibration of all sampling
and analytical apparatus where applicable and the use of spikes, replicate sample and reference
standards. The test methodologies used for this project are outlined in section 2 of this document.
Field test data has been recorded and calculated using direct entry into Microsoft Excel spreadsheets
following the procedures of the appropriate test methods. Determination of emission concentrations
has been performed using the same Microsoft Excel spreadsheets which are partially supplied as an
attachment to this report. More detailed information can be supplied upon request.
QA/QC checks for this project will use validation techniques and criteria appropriate to the type of
data and the purpose of the measurement to approve the test report. Records of all data will be
maintained. Complete chain of custody (COC) procedures has been followed to document the entire
custodial history of each sample. The COC forms also served as a laboratory sheet detailing sample
ID and analysis requirements.
Table 11: Sampling data QA/QC checklist
Sampling Data QA/QC Checklist Comment
Use of appropriate test methods Yes
‘Normal’ operation of the process being tested Yes – as instructed by client
Use of properly operating and calibrated test equipment Yes
Use of high purity reagents Yes
Performance of leak checks post sample (at least) Yes
Table 12: Laboratory data QA/QC checklist
Laboratory Data QA/QC Checklist Comment
Use of appropriate analytical methods Yes
Use of properly operating and calibrated analytical equipment Yes
Precision and accuracy comparable to that achieved in similar
projects Yes
Accurate reporting Yes
Source Emissions Monitoring – Boral Wyee
Unit 7, 142 Tennyson Memorial Avenue – Tennyson – Queensland – 4105
AB
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4 DEFINITIONS
The following terms and abbreviations may be used in this report:
Table 13: Definitions
Symbol Definition
< The analytes tested for was not detected; the value stated is the reportable limit of detection
Am3 Gas volume in cubic metres at measured conditions
AS Australian Standard
BH Back half of sample train (filter holder and impingers) (referred to during sample recovery)
oC Degrees Celsius
CARB California Air Resources Board methods
dscm dry standard cubic meters
FH Front half of sample train (probe and filter holder) (referred to during sample recovery)
f/ml Fibres per millilitre
g Grams
kg Kilograms
m Metres
m3 actual gas volume in cubic metres as measured
mbar Millibars
mg Milligrams (10-3 grams)
min Minute
ml Millilitres
mmH2O Millimetres of water
Mole SI unit that measures the amount of substance
N/A Not applicable
ng Nanograms (10-9 grams)
NATO North Atlantic Treaty Organisation
NIOSH National institute for occupational safety and health (USA)
Nm3 Gas volume in dry cubic metres at standard temperature and pressure (0°C and 101.3 kPa)
NMI National Measurement Institute
NM VOC Non methane volatile organic compound
NR Not required on this occasion
OSHA Occupational Safety and Health Act
ou Odour unit
PCDD Polychlorinated dibenzo-p-dioxin
PCDF Polychlorinated dibenzofuran
PM Particulate matter
ppb Parts per billion
ppm Parts per million
sec Second
Sm3 Gas volume in dry cubic metres at standard temperature and pressure (0°C and 101.3 kPa) and
corrected to a standardised value (e.g. 15% O2)
STP Standard temperature and pressure (0°C and 101.3 kPa)
TO USEPA air toxics method
TWA Time weighted average
USEPA United States Environmental Protection Authority
Source Emissions Monitoring – Boral Wyee
Project ID 10514 | R_2 12
5 RESULTS
Table 14 - 17 present a summary of the isokinetic and gases analyser sample runs.
Table 14: Test results – Kiln stack manual samples
Unit sampled Kiln Stack
Sampling date 19/07/2016 19/07/2016 19/07/2016 19/07/2016 19/07/2016
Begin sampling time 10:25 12:40 10:25 10:25 10:25 Units
End sampling time 11:25 13:40 11:25 11:25 11:25
Equipment rated capacity Not specified
Equipment load during sampling 35 cars per shift
Sampling plane diameter 970 mm
Sampling plane area 0.74 m2
Sampling port size, number and depth 100, 2, 130 mm , - , mm
Duct orientation and shape Vertical, Circular -
No. of traverse points sampled 12 -
Parameters Units PM-total - RUN Ftotal - RUN SO2 - RUN SO3 (as H2SO4) PM10 Average results
Temperature °C 151 150 151 151 151 151
Carbon dioxide vol-% 0.5 1.3 0.5 0.5 1 0.90
Oxygen vol-% 19.5 18.1 19.5 19.5 20 18.8
Stack gas water vapour vol-% 4.3 6.1 4.3 4.3 4 5.2
Gas molecular weight - dry g/g mole 28.9 28.9 28.9 28.9 29 29
Gas density - dry kg/m3 1.29 1.29 1.29 1.29 1 1.3
Average velocity m/s 17 17 17 17 17 17
Volumetric flow rate - actual, wet m3/min 756 760 756 756 756 758
Volumetric flow rate - dry & STP dsm3/min 470 466 470 470 470 468
Total sampling time min 60 60 60 60 60 60
Isokinetic rate (90%-110%) % 99 101 99 99 99 100
Isokinetic rate (80%-120%) % - - - - - -
Cut point µm - - - - - -
Results mg/Nm3 24.4 10.2 29.3 6.74 6.77 -
Release limit mg/Nm3 250 50 - - - -
Emission rate g/s 0.191 0.079 0.23 0.05 0.05
Source Emissions Monitoring – Boral Wyee
Project ID 10514 | R_2 13
Table 15: Test results – Kiln stack gases
Unit sampled Kiln Stack
Sampling date 19/07/2016
Begin sampling time 12:27:37
End sampling time 13:40:37
Equipment rated capacity Not specified
Equipment load during sampling 35 cars per shift
Parameters Units
Temperature °C 151
Carbon dioxide vol-% 0.904
Oxygen vol-% 18.8
Stack gas water vapour vol-% 5.2
Gas molecular weight - dry g/g mole 28.9
Gas density - dry kg/m3 1.29
Average velocity m/s 17
Volumetric flow rate - wet m3/min 758
Volumetric flow rate - dry dsm3/min 468
Sampling time min 1:13:00
Sample result Release Limit
Carbon monoxide (CO) mg/Nm3 33 -
Emission rate g/s 0.25 -
Sample result Release Limit
Nitrogen Oxides (NOx as NO2) mg/Nm3 55 2,500
Emission rate g/s 0.43 -
Source Emissions Monitoring – Boral Wyee
Project ID 10514 | R_2 14
Table 16: Test results – Dryer stack manual samples
Unit sampled Dryer (EF-VE-2)
Sampling date 20/07/2016 19/07/2016 20/07/2016 20/07/2016 20/07/2016
Begin sampling time 8:00 14:30 8:00 8:00 8:00 Units
End sampling time 9:20 15:50 9:20 9:20 9:20
Equipment rated capacity Not specified
Equipment load during sampling Normal operation
Sampling plane diameter 890 mm
Sampling plane area 0.62 m2
Sampling port size, number and depth 100, 2, 90 mm , - , mm
Duct orientation and shape Vertical, Circular -
No. of traverse points sampled 16 -
Parameters Units PM-total - RUN Ftotal - RUN SO2 - RUN SO3 (as H2SO4) PM10 Average results
Temperature °C 31 32 31 31 31 32
Carbon dioxide vol-% 0.010 0.010 0.010 0.010 0 0.010
Oxygen vol-% 21.0 21.0 21.0 21.0 21 21.0
Stack gas water vapour vol-% 3.1 6.8 3.1 3.1 3 4.9
Gas molecular weight - dry g/g mole 28.8 28.8 28.8 28.8 29 28.8
Gas density - dry kg/m3 1.29 1.29 1.29 1.29 1 1.29
Average velocity m/s 7.2 4.8 7.2 7.2 7 6.0
Volumetric flow rate - wet m3/min 269 179 269 269 269 224
Volumetric flow rate - dry dsm3/min 234 150 234 234 234 192
Sampling time min 80 80 80 80 80 80
Isokinetic rate (90%-110%) % 100 103 100 100 100 102
Isokinetic rate (80%-120%) % - - - - - -
Cut point µm - - - - - -
Results mg/Nm3 0.735 < 0.706 0.755 0.140 < 0.735 -
Release limit mg/Nm3 - - - - -
Emission rate g/s 0.0029 < 0.0018 0.0029 0.00055 < 0.0029
Source Emissions Monitoring – Boral Wyee
Project ID 10514 | R_2 15
Table 17: Test results – Dryer stack gases
Unit sampled Dryer (EF-VE-2)
Sampling date 19/07/2016
Begin sampling time 14:30:37
End sampling time 15:50:37
Equipment rated capacity Not specified
Equipment load during sampling Normal operation
Parameters Units
Temperature °C 32
Carbon dioxide vol-% 0.01
Oxygen vol-% 21.0
Stack gas water vapour vol-% 4.93
Gas molecular weight - dry g/g mole 28.8
Gas density - dry kg/m3 1.29
Average velocity m/s 6.0
Volumetric flow rate - wet m3/min 224
Volumetric flow rate - dry dsm3/min 192
Sampling time min 1:20:00
Concentration Release Limit
Carbon monoxide (CO) mg/Nm3 1.8 -
Emission rate g/s 0.0070 -
Concentration Release Limit
Nitrogen Oxides (NOx as NO2) mg/Nm3 < 2.1 -
Emission rate g/s < 0.0080 -
Source Emissions Monitoring – Boral Wyee
Project ID 10514 | R_2 16
Figure 4: Kiln stack gas trends
0
10
20
30
40
50
60
70
80
0
5
10
15
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25
CO
& N
Ox -
pp
m
CO
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O2 -
%
Gases Trend
CO2 O2 CO NOx
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