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.

The clarification wastewater constitutes approximately 60% of the total waste


and the various parameters of the clarification waste analyzed are as tabulated below:Table 4.0: Parameters for Effluent of Palm Oil Mill
Parameters

Sterilizer

Clarification

Hydrocyclone

Condensate

Sludge

Discharged

/
BOD30 ;

COD ;

/
/

Total solid ;
Suspended solid
;

Oil and grease ;


nitrogen
Ammonical
/
/

2500-5000

2000-5000

2000-5000

4500-5000

4000-10000

3000-5000

3500-5000

3000-5000

2500-5000

1000-5000

1500-5000

1500-5000

6000-3000

6000-3000

1500-2000

20-50

20-30

; 30-80

Total nitrogen ;

500-100

500-1000

20-30

pH

4.0-4.5

4.0-4.5

5.5-6.2

Temperature ; 0C

80-90

80-90

30

From table above, it can be seen that the clarification waste has very low pH
value, high value of BOD and solid levels. In addition, it contains about 1% of oil. The
temperature of the waste is normally above room temperature and is about 80 to 900C.
These conditions of the effluent make treatment difficult and very limited methods of
treatment either a single or a series of sludge traps where further oil can be recovered
from the waste before proceeding into a common sump to be pumped up for treatment
purpose.

4.2.2.1 Pre-Treatment of POME


The contents of POME are essentially organic and moderately biodegradable.
The biodegradability is influenced by the extent of cellulosic materials present such as
the palm fibre residues as well as the residual oil content. The effluent treatment
technologies for POME are therefore invariably combinations of physical and
biological processes. The physical treatment includes pre-treatment steps such as
screening, sedimentation and oil removal in oil traps prior to the secondary treatment
in biological treatment systems.
Sand and grit that accompany the FFB and residual oil are removed in a sand
trap and/or oil trap. The oil trap consists of a baffled pit or sump that retains the
wastewater for at least 10 hours. Hydraulic retention times (HRTs) of about 1 to 2 days
are preferable for more effective oil removal and minimal loss of oil to the effluent.
Steam is sometimes used to heat oil bearing wastewaters in the oil trap to
improve oil separation and release. The oil that floats to the wastewater surface is
manually skimmed-off and recovered on a regular basis and stored in drums. The
skimmed oil is either sent to the clarifiers for further processing, or sold to soap
manufacturers as raw material. The sand, grit and other settled solids are disposed-off
onto the plantation land.

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4.2.2.2 Biological Treatment of POME


The organic content of POME is generally biodegradable and treatment is
based on anaerobic, aerobic and facultative processes. The processes are essentially
biochemical and rely on the enhanced growth and metabolic activities of suitable
microorganisms to breakdown the organic matter into simple end-products gases such
as methane, carbon dioxide and hydrogen sulphide, and water.
The microorganisms involved are primarily bacteria and algae which result in
the production of excess biomass (microbial cells) that needs to be disposed-off in the
form of sludge. This sludge can be appropriately land-applied in the palm oil mill
plantation as soil conditioner. Currently, there are various treatment alternatives
include the land disposal of either raw or partially treated wastewater, physical or
chemical treatment, biological treatment, incineration or others. However, the system
which is commonly adopted by most oil mills is 100% biological treatment system
with emphasis on the anaerobic digestion as the primary treatment The biological
treatments in Mempaga Palm Oil Mill involve four stages of ponds which are mixing,
anaerobic, facultative and aerobic stage. (Figure 4.0)
a) Mixing Pond
The first stage in biological treatment is the mixing stage. Waste
effluent from the clarification and sterilizer station are pumped to the cooling
pond where they are cooled in 1 day or less and then mixed with the recycled
supernatant liquor from the anaerobic ponds in the ratio 1:1. This mixture is
retained in 1 day before going into the anaerobic ponds. The purpose of this
pond is to increase the initial pH of the as well as to give a sort of buffer effect
to the anaerobic pond whenever the raw effluent is charged into the system. In
order to achieve this, the mixing has to be carried out very consistently inside
the mixing pond.

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b) Anaerobic Pond
The mixed waste is exposed to anaerobic reactions inside the anaerobic
pond for a certain retention time. The waste will be decomposed anaerobically
by anaerobic bacteria. Anaerobic breakdown of the organic matter consists of
several stages, acidification and a gasification stage which produce primarily
methane (CH4) and carbon dioxide (CO2) and very little of hydrogen sulphide
(H2S). During the acidification stage of organic matter will be decomposed into
new cells which are called acid formers and together with organic acids. The
organic acids will react with hydrogen gas to form other new cells which are
called methane formers and at the same time methane and carbon dioxide are
liberated. The methane bacteria are sensitive to acidic conditions and therefore
the pH of pond should not be allowed drop below 6.75.
&

The retention time depends on initial BOD loading of the wastes


efficient removal of oil in the raw effluent and the type of anaerobic digester
used. In the case of steel digester the retention time is in the region of 20 days
while for the earth ponds, the retention time is between 45 60 days. It is
expected that this anaerobic digestion shall be able to reduce the BOD from
25000 to 2000 ppm or below than 2000 ppm.
c) Facultative Pond
Term of facultative refers to a mixture of anaerobic and aerobic
condition. The anaerobic conditions exist towards the bottom while the aerobic
conditions are maintained in the upper layer. Facultative pond is designed to
operate at lower BOD input than the anaerobic pond and this allows dissolved
oxygen to persist throughout greater part of the liquid depth, at least during the

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day time. Solids entering the pond will deposit on the bottom and organic
matter in this sludge layer will undergo anaerobic breakdown.
Soluble fermentation products will enter the liquid layer above and then
broken down anaerobically along the soluble and colloidal organic in the
incoming waste from the supernatant liquor. Under properly controlled
conditions the growth of algae occurs in the facultative pond and will supply
oxygen for further bacterial breakdown of the organic matter. The retention
period of this facultative stage is about 20 days and the depth of 8 feet is
expected good BOD removal shall occur.
d) Algae Pond
After the facultative reaction, the waste is passed to a series of two or
more shallows ponds known as algae ponds which is the aerobic stage. It has a
retention time of 7 days for each. These algae ponds are wholly in aerobic
condition throughout of its depth of 4 ft. In this pond, the organic loading is
very low and therefore with the help of sunlight to allow the existence of the
interaction between the bacteria and algae whereby the photosynthesis algae
utilize the CO2 released in bacterial respiration and the benefit for the bacteria
through the releasing of oxygen by algae. It is expected the final pond shall be
able to reduce the BOD and solids level to the DOEs acceptable limits.

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Figure 4.0

Process Flow Diagram of Effluent Treatment Plamt

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4.2.3 Gaseous Emission


There are two principal sources of air pollution in palm oil mills:i.

Boiler that use the waste fibre and shell materials

ii.

Incinerators that burn the empty fruit bunches (EFB) for recovery of
potash ash

Smoke and dust emissions are the main concerns due to incomplete combustion
of the solid waste materials. Palm oil mill is generally self-sufficient in terms of energy
requirements due to the availability of adequate quantities of the fibre and shell
materials that are used as solid fuel in the steam boiler.

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CHAPTER 5

ANALYSIS IN LABORATORY

5.1

Introduction

In palm oil mill, the effectiveness of an assessment oil extraction and quality of
products where production oil and kernel had been carried out by analyzing the sample
everyday in palm oil mill laboratory. The quality of palm oil manufactures of edible
products made from palm oil desire to purchase oil which will refine consistently well,
and at reasonable cost to facilitate the making of end-products have good colour, flavor
and keeping properties. In addition, the quality in palm oil can be defined as the extent
which properties of the oil meet consumer requirements.
For quality control purposes it is obvious that regular samples of the oil as
produced and sent to the storage tanks from the factory must be taken and analyzed
and that, further samples of each batch of oil despatched from the mill after storage in
these tanks must be examined.
In addition representatives samples of kernel as bagged must be examined and
if appreciable delay occurs before these kernels leave the mill it may be also desirable
to sample and analyze the kernels as despatched.

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For process control, it is necessary to sample the waste product discharged for
evaluation of oil and kernel losses and sludge. The percentage of oil loss is defined at
sludge mixture raw material, sludge of condensate and sludge of trap. The sample is
taken at light particle transport system, fibre cyclone and wet shell for calculating the
percentage of kernel loss. The other analysis is mass passing to digester (MPD)
analysis. MPD analysis is very important to ensure the quality of fruit have been
thrashed out of sterilized bunches is controlled.

5.2

Palm Oil Analysis

5.2.1 Free Fatty Acid (FFA)

Free fatty acids are formed by splitting of the fatty acids from triglycerides and
FFA tests assess the degree of this acid formation. FFA has been principal criterion of
palm oil quality. An upper limit of 5% FFA at port is imposed by consumers and oil
with FFA at higher than 5% is considered inferior and a discount is levied because of
greater loss of oil during refining. Procedures of oil about 3% FFA at mill end and 2%
for acid increase during storage and transit must be achieved for keeping within 5%
which is standard percentage of FFA meet consumers requirement.
FFA is determined by direct titration with sodium hydroxide (NaOH) using
phenolphthalein indicator. FFA is calculated as palmitic acid from
formula:.

% FFA
Where,

=
t

= titre in mL

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= normality of sodium hydroxide

= weight of oil used

5.2.2 Volatile Matter (VM)

Volatile matter in palm oil is given by the mass lost on heating in oven at 105
20C, expressed as percentage of the mass of the oil.
It is possible to produce oils with extremely low moisture contents, but values
in the range 0.07- 0.13% are preferred in Malaysia because it has been found that
lower moisture contents can results in rapid increase in FFA of oil and reduce
bleachability.

5.2.3 Dirt

The insoluble impurities are determined by filtration through glass fibre filter
and calculated as weight percentage of the oil. The maximum dirt content allowed has
been 0.01% and dirt content higher than this encourage the growth of lipolytic microorganisms which is responsible for the increasing of FFA, by acting as a source of
nutrients for the lipolytic micro-organisms.

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5.2.4 Deterioration of Bleacheability Index (DOBI)

Deterioration of Bleacheability Index (DOBI) is a ratio of absorbance at


wavelength, maximum and minimum equal to 446 nm and 269 respectively. A UVvisible system of slits focuses the desired wavelength on the palm oil sample cell. In a
this typical double beams instrument, the light emanating from the light source is split
into two beams, which are the sample beams, which are the sample beam (mixture of
palm oil and hexane) and the reference beam (hexane only). When there is no sample
in the reference beam, the detected light is taken into be equal to the intensity of light
entering the sample. (IO)

5.3

Kernel Analysis

5.3.1 Free Fatty Acid (FFA)


For determination of FFA in kernel, method and calculation are difference than
in palm oil. 50 mL of denaturned alcohol and 4 drops of phenolphthalein are added
into 250 mL Erlenmeyer flask 0.1 N potassium hydroxide solution is dropped until the
solution retains a faint pink colour. The volume of potassium hydroxide used in the
titration is recorded.

2
0
-

Where V

= mL of 0.1 N potassium hydroxide solution used in the titration

= factor of 0.1 N potassium hydroxide solution

= weight of empty extraction flask

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= weight of extraction flask + oil

5.3.2 Determination of Moisture Content


The method involves drying the kernel at 1030C and as such does not
differentiate between moisture and other volatile matter driven off under the conditions
of the test. The slices from about 50 kernels are cut using a sharp knife. The thickness
of the slices should be less than 1 mm and the total weight of the slices should be 10 to
12 g. The slices kernel is weighted on an analytical balance. The dish is placed in an
oven is maintained at 103 20C and dried for 4 hours. Then the dish is placed in
desiccators and allowed to cool and after that the dish and its contents are weighted
again.
The percentage calculation of moisture:-

( -

=)

100

( -

Where A

= weight of empty dish

= weight of dish + kernel slices before drying

= weight of dish + kernel slices after drying

5.3.3 Determination of Shell and Dirt (Total Dirt) in Palm Kernels


1 0 kg of the kernel sample is weighted and spread on the clean surface. The
sample is separated kernel, half cracked, uncracked nut, loose shell and dirt (fibre and
other foreign matter). The shell is removed from the half cracked and uncracked nuts

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and added to the loose shell and dirt. The shell and dirt are weighted together to the
nearest 0.5 g.
Formula in calculating dirt in palm kernel:-

)=
100

Where A
B

5.4

= weight of shell and dirt in the sample (g)


= weight of sample taken for analysis (g)

Losses Analysis in Palm Oil Mill

5.4.1 Oil Loss


The oil loss in the sterilizer condensate is excluded from the list of
measurement losses used to calculate the efficiency. Oil loss is expressed as the
amount of oil per dry matter (ODM). The amounts of oil on this extraction are given as
percentage. The oil can be obtained by calculating the amount of loss, while the dry
matter can be measured by subtracting 100 with the volatile moisture (VM). Notice
that the values of VM are from the deviation between sludge and crucible before and
after heating.
According to Figure 5.0, the sample is taken and weighted using an analytical
balance. Then the sample is put into oven at 1050C for 16 hours. The dry sample is
weighted on an analytical balance before extracted.

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Figure 5.0

Procedures in Calculating Oil Loss

(%)
10
(%)

(
)

( )
%
= 100 -

10

5.4.2 Kernel Loss

The percentage of kernel loss is determined in light particle transport system


(LPTS), fibre cyclone and wet shell. 1 kg of sample is taken from LPTS, fibre cyclone
and wet shell. In LPTS, factors that can cause the kernel loss are high percentage of

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broken nuts in cracked mixture. Besides, when the amount of cracked mixture entering
LPTS is high, it also can cause the kernel loss. The limit percentage of LPTS on
sample should be lower than 2%. For determination of kernel loss in LPTS, the
sample was separated into 2 parts according to its broken kernel and free shell. The
mass of broken kernel is weighted. The formula in calculating kernel loss in LPTS:-

100

For the case of fibre cyclone, the low efficiency of hydrocyclone is one of the
factor for kernel loss. Moreover, the kernel loss is high when FFB are not well-treated
during sterilization. The percentage of kernel loss in fibre cyclone should not higher
than 2%. For determination of kernel loss in fibre cyclone, the sample was separated
into broken kernels, half nuts and uncracked nuts. The mass of each is weighted. The
percentage of kernel loss in fibre cyclone is calculated as follows:Let,

So,

+
%

level

Mass of broken nuts

=a

Mass of half nuts

=b

Mass of uncracked nuts

=c

a/1

= mass a

b/3

= mass b

c/2

= mass c
+
=

10

In wet shell production, the mis-opening of vortex finder and cone


0
adjustment are some factors that can influence the kernel loss. the kernel loss in wet
shell must be followed the limit which is 3%. The last percentage of kernel loss is

uncracked

determined in wet shell which is separated into broken kernels, half nuts,
nuts and whole kernels. Mass of each is weighted. The percentage of kernel loss in wet

shell is obtained by counting the number of each category of kernels thus obtains
as
below:Let,

Mass of broken nuts

=a

Mass of half nuts

=b

Mass of uncracked nuts

=c

Mass of whole kernel s

=d

So,

a/1

= mass a

b/3

= mass b

c/2

= mass c

d/1

= mass d
+

+
%

10

In preventing the kernel loss, nut cacker should be well-function. The position
of damper in LPTS part should be checked. Besides, the air suction should be
maximized in fibre cyclone to reduce the fibre into nut cracker. The last suggestion to
prevent the kernel loss is controlled the cone level adjustment in hyrocyclone and the
vortex finder.

5.5

Mass Passing to Digester (MPD) Analysis


MPD is total fruit, calyx leaves, spikelets and undeveloped fruit that have been

thrashed out or sterilized bunches i.e. the total sterilized fruit without the empty bunch.
The sample of MPD analysis is taken at the thresher conveyor before the fruit elevator
in 1 kg. Each sample should be analyzed for percentage by weight of whole fruit with

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nuts and nuts. For whole fruit with nut, mesocarp is squeezed out from each fruit.
While for the nuts, there are separated normal parthenocarps (undeveloped fruit and
non-oil bearing), abnormal parthenocarps (normal whole fruit without nut and oil
bearing) and calyx leaves and spikelets. (Example of report at Appendix)

5.6

Boiler Water Test

The boiler and softener water must be tested twice a day, once in the morning
and the other one in the evening. The hardness of the water after softener must be
checked daily to make sure that it is below than 5 ppm, and then the softeners must be
regenerated either by the laboratory or the boiler water chargeman.
The water hardness is defined by the capacity of water to precipitate soap. The
ionic species in the water causing the precipitation was later found to be primarily
calcium and magnesium. Certain other ions species that were found to contribute to the
water hardness are iron, zinc and manganese. The measure and control of water
hardness is essential to prevent scaling and clogging in boiler.
The hardness level as ppm calcium carbonate, CaCO3 is determining by
titration with EDTA. The solution is first added to buffer solution to meet the pH
requirement which is 10. The indicator chelates with the metal ions such as magnesium
or calcium to form a red colour solution. The metal ions complex with EDTA as it was
added. After all free metal have been complexed with the indicator to form a blue
colour solution. The colour changed from red to blue is the end point of the titration.
A sulphite concentration must be maintained from 30 to 50 ppm. The value
must be in range to prevent pitting and oxidation of metal components as in the boiler
water. High level of sulphite made the pH is lower which an acidic and promote the

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corrosion. In determination of sulphite ions, iodometric method is used. Iodide ions


will react with iodate ions in the present of sulphuric acid to form iodine. The sulphite
presents in the water sample reduce the iodine to iodate. Exceed of iodate, ions will
generate additional iodine, which to form a blue complex with starch. The end point of
titration is determined by changing of colour.
Caustic alkalinity can be measured as phenolphthalein alkalinity and total
alkalinity. This is determining by neutralizing the sample to a pH 8.3 using a dilute
acid solution and a phenolphthalein as an indicator. This process converts hydroxide
ions to water and carbonate ions to bicarbonate ions.
Since bicarbonate ions can be converted to carbonic acid with additional
hydrochloric acid, the caustic alkalinity measures total hydroxide ions but only half of
the bicarbonate contribution. The completely convert the carbonate ions, hydrochloric
acid is added until the ph of the sample is 4.5.

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CHAPTER 6

CONCLUSION AND RECOMMENDATIONS

6.1

Conclusion

Mempaga Palm Oil Mill one of the branch in Felda Palm Industries Sdn. Bhd.
Felda is one of the biggest corporate company in Malaysia. By training under Feldas
scheme, a lot of knowledge and experience can be gained and built. Moreover
Mempaga Palm Oil Mill is suitable for the future engineer especially from Universiti
Malaysia Pahang to choose as place for industrial training. From this industrial
training, student can learn the process of palm oil production. The daily analysis is
done to monitor and determine the quality of palm oil processes in this mill. Besides,
the laboratory attendances also analyzed the boiler feed water and softener water to
make sure that the steam generated has sufficient chemical. Student also is exposed on
how to treat the waste product to produce beneficial things.
In addition, the knowledge can be gained for the mill maintenance example in
controlling the losses from mixed raw material and sludge condensate. Besides, I also
learned how to overcome the problem example to transfer the storage oil either bulk
storage 1, 2 or 3. This is one of the important things as engineer in palm oil mill to
decide which bulk storage tank needed to be transferred.

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6.2

Recommendations

Based on experience for a few months in Mempaga Palm Oil Mill, these
recommendations can be taken into consideration to upgrade future practical training
in this mill:i.

Student should be given a task related to the process in palm oil mill which is
appropriate with the course taken.

ii.

Student also should be involved directly for the responsibility as engineer.

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REFERENCES

Buku Rekod Analisa BST (2008). Mempaga Palm Oil Mill


Buku Rekod Analisa DOBI (2008). Mempaga Palm Oil Mill
Buku Rekod Analisa Kernel (2008). Mempaga Palm Oil Mill
Cara Memproses Buah Sawit (2001). Mempaga Palm Oil Mill
Chemical Safety Data Sheet (2001); AMT Technologies Sdn.Bhd
Manual Operasi (Effluent Management System), Felda Palm Industries Sdn.Bhd
Manual Operasi (Makmal), Felda Palm Industries Sdn.Bhd
M.I Thani, R Hussin, W.R.Wan Ibrahim, M.S.Sulaiman (1999) Industrial Processes &
The Environment 3rd Edition. Department of Environment, Ministry of Science,
Technology and The Environment, Malaysia.
Palm Oil Research Institute Malaysia (1983), Test Method for Palm Oil and Palm Oil
Products Ministry of Primary Industries Malaysia.
Quality Control Instructions Manual, Volume 1(1983), Perbadanan Kilang Felda
Retrieved on JULY 16, 2008, from http://www.fao.org/DOCREP

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APPENDIX A
FELDA PALM INDUSTRIES SDN BHD
KILANG SAWIT MEMPAGA
RUMUSAN ANALISA MPD
No Borang:
FPI/L4/QMS-MPD1
Pind 0

Tarikh

Berat
Sample

Ripe Fruitlets With Nut


Mesocarp
Berat
[gm]

TRUE

Ripe Fruitlets With Nut

Nuts
Berat
[gm]

Mesocarp
TRUE

Berat
[gm]

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TRUE

Abn Path
Berat

Nuts
Berat
[gm]

TRUE

[gm]

Norm.
Path
Berat
[gm
]

Cal.
Leaves
Berat
%

[gm]

Oil
Content
Ripe

Unripe

APPENDIX B
KILANG SAWIT MEMPAGA
LAPURAN HARIAN ANALISA KERNEL / FIBRE
TARIKH :
BIL :

SAMPLE

E
1.

BERAT
SAMPL

BROKEN
NUT

NUT

TOTAL
NUT

FIBRE /
NUT %

BROKEN

HALF

UNCRACKED

TOTAL

NUT

NUT

NUT

KERNEL %

PRESS
CAKE
1
2
3
4
5
6

2.

FIBRE
CYCLONE

BERAT
SAMPLE

LINE 1
LINE 2
3.

L.T.P.S

BERAT SAMPLE

BROKEN KERNEL

LINE 1
LINE 2
4.

CRACKED

BERAT

BROKEN

HALF

UNCRACKED

WHOLE

TOTAL

MIXTURE

SAMPLE

KERNEL

NUT

NUT

KERNEL

KERNEL %

BEFORE

BERAT

BROKEN

HALF

UNCRACKED

FREE

TOTAL

HYDRO

SAMPLE

KERNEL

NUT

NUT

SHELL

DIRT

WET

BERAT

BROKEN

HALF

UNCRACKED

WHOLE

TOTAL

SHELLS

SAMPLE

KERNEL

NUT

NUT

KERNEL

LOSS

WET

BERAT

BROKEN

HALF

UNCRACKED

FREE

TOTAL

KERNEL

SAMPLE

KERNEL

NUT

NUT

SHELL

DIRT

PROD.

BERAT

BROKEN

HALF

UNCRACKED

FREE

TOTAL

KERNEL

SAMPLE

KERNEL

NUT

NUT

SHELL

DIRT

1
2
3
4
5.

CYCLONE
LINE 1
LINE 2
6.

1
2
3
4
7.

1
2
3
4
8.

1
2
3
4
5
6

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