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Article history: In this paper we studied the effect of catalyst particles on the enhancement of the gas–liquid mass
Received 4 August 2015 transfer due to a first order heterogeneously catalyzed reaction. The enhancement factor was obtained by
Received in revised form solving the liquid side unsteady reaction-diffusion equation accounting for the presence of the particles.
12 January 2016
The results are compared with an analytical model that was derived assuming a homogeneous dis-
Accepted 16 January 2016
Available online 9 February 2016
tribution of the particles in the liquid film. It was found that the enhancement factor increases with
increasing catalyst concentration and increasing rate of reaction, as expected. As the particle diameter is
Keywords: increased, the enhancement factor decreases due to an increasing degree of diffusion limitation.
Enhancement factor The results of the homogeneous model match well with the results of the numerical simulations
Numerical simulation
within a 10% error. Therefore it is concluded that the homogeneous model can be used to predict the
Chemically enhanced mass transfer
enhancement of the mass transfer due to the presence of catalytic particles.
Three-phase transport phenomena
& 2016 Elsevier Ltd. All rights reserved.
1. Introduction engineering skills are still very worthwhile to do. One of the more
complicated multiphase systems is the so-called gas–liquid–solid
In chemical industry the importance of multiphase reactors is reactor where gaseous and liquid components are allowed to react by
eminent already for decades. Still today there are enough challenges means of a solid (supported) catalyst. A proper understanding of the
left to further improve performance of these reactors to maintain hydrodynamics, mass transfer, heat transfer, and kinetics is required
profitability and also to meet more strict (future) environmental for the proper design of such a reactor. For slurry reactors, where the
targets. Especially for reactor systems in large bulk chemical plants small catalyst particles are dispersed throughout the liquid phase, the
every small fraction in reactor performance increase can be a sub- gas to liquid mass transfer is one of the critical aspects.
stantial overall improvement. Not only in increased reactor yield as It is known that the rate of gas–liquid mass transfer can be sig-
such but also separation downstream can be positively affected. nificantly influenced by the presence of small particles in the liquid,
Studies to support the fundamental understanding of the mechan- either being gas-absorbing or reactive particles (Ramachandran, 2007;
isms taking place in the reactors and at the same time extending Ruthiya et al., 2004; Wimmers et al., 1984, 1988; Wimmers and For-
tuin, 1988b; Holstvoogd et al., 1988; Holstvoogd and Van Swaaij, 1990).
n
Corresponding author. The presence of the small particles near the gas–liquid interface can
E-mail address: N.G.Deen@tue.nl (N.G. Deen). increase the liquid side concentration gradient of the transferred
http://dx.doi.org/10.1016/j.ces.2016.01.043
0009-2509/& 2016 Elsevier Ltd. All rights reserved.
234 P.W.A.M. Wenmakers et al. / Chemical Engineering Science 145 (2016) 233–244
component, thereby increasing the mass transfer rate. Depending on design. Heterogeneously catalyzed reactions are abundant in
the lyophobicity the particles can actually adhere to the gas–liquid industry for e.g. oxidation, hydrogenation, and Fischer–Tropsch, see
surface (Wimmers and Fortuin, 1988a; Omota et al. 2006a,b; Verrelli e.g. Youssef et al. (2013).
et al., 2011), thus reducing the diffusion distance between the
gas–liquid interface and the (catalyst) particles. The enhancement of
mass transfer due to the presence of catalyst particles near the gas– 2. Theory
liquid surface has been investigated in a couple of earlier papers, see
e.g. Ruthiya et al. (2004, 2005), Ramachandran (2007). Especially The enhancement of gas absorption into the liquid phase by
Ramachandran (2007) presents a thorough review on the modelling means of heterogeneous catalyst particles has already been stu-
approaches followed. Typically a continuum approach is adopted died for many decades, see e.g. Ruthiya et al. (2005), Ramachan-
where the steady state diffusion-reaction equation is solved. In some dran (2007), Wimmers et al. (1984), both experimentally and
cases also the effect of internal diffusion is taken into account via the theoretically. In these publications a number of modeling
effectiveness factor. However, the presence of the particles themselves approaches have been followed to describe the enhancement of
and the reaction occurring within the particles will result in the pre- gas absorption. Ramachandran (2007) gives an overview of the
sence of spatial concentration gradients in all directions, not only various methodologies applied. All of these models, in one way or
perpendicular to the gas–liquid interface. The particles themselves can another, describe the enhancement of the absorption by con-
also be seen as an obstruction within the fluid, thus hindering mass centration depletion within the film layer. The different models
transfer towards the bulk of the liquid. These aspects are typically not vary in level of complexity from pseudo-homogeneous models to
taken into account within the available models. Also, as stated earlier, more complex cell models which take into account various dis-
the internal diffusion is approximated by the effectiveness factor tances of the catalyst particle from the gas–liquid interface. Some
approach which per definition does not account for local concentra-
of these models employ the classical resistances in series approach
tion variations around the catalyst particle.
(see Fig. 1) to describe the observed rate of absorption:
Nowadays, the computing power and the availability of com-
mercial software allows for a much more detailed consideration of 1 1 1 1 pA
RAv ¼ þ þ ð1Þ
transport phenomena and related problems. The integration kgl agl kls als ηkr HA
between software packages facilitates the accurate representation
of more complex geometrical structures and to arrange for a while others start from the stationary reaction-diffusion equation. In
sequence of simulations. Therefore, a large number of simulations some studies even the effect of internal diffusion limitation by means
can be conducted and run even on a standard workstation. of the so-called effectiveness factor (η) is accounted for. These studies
Therefore, the effect of particles near the gas–liquid interface can typically have derived their relations on (pseudo) steady state
now be studied numerically in more detail. assumptions. In this work two approaches have been followed to
In the present study the enhancement of gas–liquid mass study the enhancement of the gas absorption by catalyst particles
transfer was studied using 3D unsteady simulations using the residing inside the liquid-side mass transfer boundary layer:
COMSOL Multiphysics software environment. The diffusion of the
gaseous component through a suspension of catalyst particles was 1. Detailed unsteady simulation of diffusion into a liquid film filled
studied for various cases, viz. effect of: with reactive catalyst particles using COMSOL Multiphysics.
2. Derivation of an unsteady homogeneous model for diffusion
1. particle configuration, i.e. randomly distributed particles versus into a liquid containing catalyst particles.
closely packed particles,
2. particle diameter, 2.1. Numerical model
3. particle volume fraction,
4. rate of reaction, i.e. different reaction rate coefficients (this also COMSOL Multiphysics 4.3a has been used to model the diffu-
directly relates to the degree of internal diffusion limitation), and sion of the gas into a liquid film filled with catalyst particles. For
5. liquid diffusivity. practical reasons only a small part of a gas–liquid interface has
been modelled, therefore curvature of the gas–liquid interface is
In addition to the 3D simulations a homogenous model was neglected, i.e. the gas–liquid interface has been modelled as a flat
derived that incorporates the combined effects of the catalyst interface. The catalyst particles are assumed spherical and homo-
particles and internal diffusion limitation on the overall rate of geneous, i.e. no pores have been modelled explicitly where the
mass transfer through the gas–liquid interface. The results of the (effective) diffusion coefficient throughout the solid is assumed to
homogeneous model have been compared with the rigorous be constant. The presence of the solid catalyst particles within the
simulations in COMSOL Multiphysics. liquid film has been represented in two ways:
The outline of our paper is as follows: first the adapted mod-
elling approach for gas–liquid mass transfer through a suspension 1. The particles are randomly distributed.
of catalyst particles is described. Subsequently the derivation of
the homogeneous model for the enhancement factor for gas–
liquid mass transfer is presented, followed by a comparison of the
results obtained from the homogeneous and detailed models.
Finally it is shown that the homogeneous model is capable of
providing adequate estimates of the enhancement factor using
either graphs or (relatively) simple algebraic expressions.
The presented graphs and expressions can be used to estimate
the degree of enhancement on gas–liquid mass transfer for a ple-
thora of reactor systems, since no assumptions are made on this
part. Using knowledge (or assumptions) on the local catalyst con-
centration and the kinetics thus allows the engineer to account for Fig. 1. Schematic representation of the concentration profile for a heterogeneously
gas–liquid mass transfer enhancement, resulting in a more accurate catalyzed gas–liquid reaction, showing the resistances in series.
P.W.A.M. Wenmakers et al. / Chemical Engineering Science 145 (2016) 233–244 235
2. The particles are closely packed in a hexagonal packing near the continuum (Crank, 1975, p. 271):
gas–liquid interface. This can be considered as an extreme limit
1 þ 2θ
of the particle configuration. Ds ¼ Dl ð4Þ
1θ
In this way two extreme cases have been taken into account, with
either the particles are distributed evenly throughout the liquid or
Dp Dl
the particles collect and organize themselves in a close packing θ ¼ εp ð5Þ
near the gas–liquid interface. If catalyst particles are lyophilic they Dp þ 2Dl
have the tendency to remain distributed throughout the liquid, In this way both the diffusivity of the solid catalyst particles
whereas if the catalyst particles are lyophobic they have a higher and the diffusivity of the liquid have been accounted for. In
tendency to adhere to the gas–liquid interface (Ruthiya et al., experiments, typically a weight fraction xp is used instead of a
2005, 2004). By assuming that the catalyst particles stack in a volume fraction. The volume fraction εp is obtained using:
hexagonal close packing the most extreme case has been taken
into account with respect to catalyst concentration near the gas– xp
liquid interface. Fig. 2 shows examples of the (a) random and ρp
εp ¼ ð6Þ
(b) hexagonal distribution of the particles in space. xp 1 xp
þ
For both cases the diffusion and reaction is modelled in the ρp ρl
same way using the general reaction-diffusion equation:
Now, using the following set of initial and boundary conditions:
∂C
¼ ∇ ðD∇C Þ kr C ð2Þ t ¼ 0; z Z 0; C¼0 ð7Þ
∂t
where D is Dl for the liquid and Dp for the solid, whereas the
z ¼ 0; t 4 0; C ¼ C0 ð8Þ
reaction only takes places inside the solid, viz. kr ¼0 for the
liquid phase.
z¼1 t 4 0; C¼0 ð9Þ
2.2. Homogeneous model the solution of Eq. (3) reads (Crank, 1975, p. 334):
pffiffiffi pffiffiffiffiffi 1 pffiffiffik pffiffiffiffiffi
For the homogenous model the liquid and solid parts are not C 1 z Dk z z
¼ e s erfc pffiffiffiffiffiffiffi kt þ ez Ds erfc pffiffiffiffiffiffiffi þ kt
considered separately. It is assumed that the reaction occurs in a C0 2 2 Ds t 2 2 Ds t
homogeneous medium where no distinction is made between the ð10Þ
liquid and solid phase. The homogeneous medium is assumed to 1
In case of no reaction, i.e. k ¼ 0 s , this expression reduces to
have constant effective properties throughout space and to be
the well-known solution for diffusion into a semi-infinite med-
semi-infinite. Only the transport by means of diffusion into the z-
ium:
direction perpendicular to the gas–liquid interface is considered.
The reaction-diffusion equation now reads: C z
¼ erfc pffiffiffiffiffiffiffi ð11Þ
∂C ∂2 C C0 2 Ds t
¼ Ds 2 kC ð3Þ
∂t ∂z The degree of enhancement of the gas absorption rate in case of
where Ds is the effective diffusion coefficient of the transferred a chemical reaction is typically quantified by means of the so-
component in the liquid–solid suspension. The value for Ds can be called enhancement factor. The enhancement factor is described as
obtained using the relation for dilute dispersed particles in a the ratio of gas flux into the liquid with and without a reaction
Fig. 2. Schematic representation of the different particle configurations used in the simulations; (a) random distribution of the particles in the fluid and (b) hexagonal
packing near the gas–liquid interface.
236 P.W.A.M. Wenmakers et al. / Chemical Engineering Science 145 (2016) 233–244
Fig. 4. 2D representation of mesh elements as used in the simulations for the case of random particles of 50 μm and 10 wt%. The figures show the random tetrahedral mesh
and the more structured boundary mesh near the gas–liquid interface and near the particle surface, the blue region represents the liquid phase and the red and purple
regions represent the particle phase. (a) Detail of the gas–liquid interface and showing a number of particles, this region represents approximately 50% of the domain; (b) a
close up of the marked region in (a) showing the boundary layer mesh near the gas–liquid interface and at the particle surface. (For interpretation of the references to color
in this figure caption, the reader is referred to the web version of this paper.)
3.7 106 elements for the randomly distributed particles and was
approximately 2.7 106 for the hexagonally distributed particles. To
account for the potentially steep gradients near the gas–liquid
interface and near the solid surface the mesh was refined at these
locations. At the gas–liquid interface a boundary layer mesh was set
of 8 elements in depth. For the particles a boundary layer mesh of
8 elements in depth was constructed on both the inside and outside
of the particle. Fig. 4 shows a 2D example of the mesh used for the
computations. Fig. 4(a) shows the random structure of the tetra-
hedral mesh and the dense boundary layer mesh at the gas–liquid
interface and near the surface of the particles. Fig. 4(b) shows a
detail of the boundary layer mesh near the gas–liquid interface and
also shows the mesh refinement near the particle surface.
The mesh quality was tested using two cases. The quality of the
boundary mesh near the gas–liquid interface was evaluated using
diffusion into a semi-infinite medium as a base case. Using the said
mesh conditions the results of COMSOL coincided with the analytical
solution. For the boundary layer near the catalyst particles a first
Fig. 5. Schematic representation of the surface domain used for averaging the flux.
order reaction was simulated with a high diffusivity in the liquid
phase. Also here the results between COSMOL and the textbook 0:2 o t r 1Δt ¼ 0:1 s ð46Þ
solutions matched well. Since the gradients will be steepest in the
catalyst particle due to the presence of a reaction no issues are
1 o t r 10Δt ¼ 1 s ð47Þ
expected with respect to the liquid side mesh of the catalyst particles.
Eq. (2) has been solved on the generated mesh using the GMRES The time stepping was set to strictly ensure that the results were
iterative solver incorporated in COSMOL Multiphysics. A relative evaluated at the specified time steps, whereas the solver is still free
tolerance of 0.01 and an absolute, scaled, tolerance of 0.001 was to use adaptive time steps between the specified time steps.
applied. COSMOL applies an adaptive time stepping method for
solving the model. However, the solver was forced to generate 3.3. Data analysis
output at the selected time steps shown below. In this way the
solver was forced to evaluate the solution at the desired time step, After COMSOL obtained the solution of the boundary value
preventing the need of interpolating the data. The solver applied an problem (Eq. (2)), the temporal concentration profiles can readily
adaptive time step method for the intermediate time steps. be derived. On basis of this data also the flux though the gas–liquid
interface can be determined. To account for potential spatial var-
0 o t r 0:2Δt ¼ 0:01 s ð45Þ iations of the flux at the gas–liquid interface the spatially averaged
P.W.A.M. Wenmakers et al. / Chemical Engineering Science 145 (2016) 233–244 239
Fig. 6. Example of a numerically computed concentration profile for (a) random and (b) hexagonal particle configuration. The blue circles/line corresponds to dp ¼ 50 μm and
the red squares/dashed line to dp ¼ 100 μm; k ¼1 1/s, Dl ¼ 10 8 m2/s, xp ¼10 wt%, t ¼10 s. (For interpretation of the references to color in this figure caption, the reader is
referred to the web version of this paper.)
Table 1
Parameters used in simulations.
flux is determined:
ZZ
1 ∂C
J ðtÞz ¼ 0 ¼ D dA ð48Þ
A A ∂z
To exclude any wall effects from the xz and yz oriented walls only a
part of the gas–liquid interface was used (see Fig. 5). A region was
selected which is one particle distance, dp, away from the sides. During
the time-averaging of the flux, which was done according to Eq. (16), it
was found that the flux for the first two time steps (viz. t¼ 0 and
0.01 s) was incorrect. This is a result of the large concentration gra-
dient in the very first steps of the simulation, where the boundary
value of the concentration at the gas–liquid interface is set to 1, while Fig. 7. Enhancement factor as a function of time for random (xp ¼ 10%) and hex-
the initial condition in the rest of the domain is 0. This issue has been agonal packing of particles for k¼ 10 1/s, D¼ 10 8 m2/s. The symbols correspond to
resolved by replacing the values of the (progressive) average flux for the data obtained from the numerical simulations and the lines to the analytical
the first two time steps by those for the theoretical value of diffusion model. (For interpretation of the references to color in this figure caption, the
reader is referred to the web version of this paper.)
into a semi-infinite medium as described by Eq. (18).
3.4. Model parameters 2005). Also, in case of dilute systems particles can collect in the wake
of a rising gas bubble thus resulting in a locally higher catalyst
Eq. (2) has been solved for the two particle configurations and concentration. For the diffusion coefficient a value of 6 10 9 and
various values of the particle diameter, reaction rate coefficient, 1 10 8 m2/s was used, which spans reasonable values for the dis-
liquid diffusivity, and catalyst concentration (see Table 1). The density solved gas diffusion coefficients (see e.g. Ruthiya, 2005) and allows
of the liquid and the bulk density of the particles were set to fixed
for reasonable calculation times. For the particle diameter values of
values of 1000 and 400 kg/m3, respectively, as reported by Merck for
50 and 100 μm have been used, which are on the larger side for a
10% Pd/C. The value of the effective particle diffusivity was set to a
slurry catalyst, and thus more prone to diffusion limitation. The
fixed value of 10 10 m2/s, in this way the effect of internal diffusion
limitation could be studied by varying the reaction rate coefficient. applied set of parameters is summarized in Table 1.
The values for the reaction rate coefficient were varied between Simulations have been conducted using all combinations of the
0.1 and 10 1/s to account for a range of degrees of internal diffusion parameters presented in Table 1. For the case of the hexagonal
limitation (viz. η 0:96 to η 0:18). The catalyst concentration was particle assembly the effect of catalyst concentration is omitted
varied between 1 and 10 wt%. In this way both dilute and more since the hexagonal packing implies a fixed concentration corre-
concentrated systems are taken into account (see e.g. Kantarci et al., sponding to a packing density of around 0.74.
240 P.W.A.M. Wenmakers et al. / Chemical Engineering Science 145 (2016) 233–244
Fig. 8. Enhancement factor as a function of time for particles with a random configuration for all studied cases; (left) 50 μm and (right) 100 μm. The legend of the graphs is
shown in Table 2, the symbols correspond to the numerical simulations and the lines to the analytical model. (For interpretation of the references to color in this figure
caption, the reader is referred to the web version of this paper.)
Table 2
Legend for Figs. 8 and 9.
kr [s 1]
Fig. 10. Parity plot of the enhancement factor; the solid line represents the parity
line, the dashed lines the þ/ 5% lines, and the dotted lines the þ / 10% lines. The
symbols correspond to the legend entries given in Table 2. (For interpretation of the
references to color in this figure caption, the reader is referred to the web version of
this paper.)
reference (–)
E0 enhancement factor with no particles present as
3
reference (–)
H height of computational domain (m)
HA Henry coefficient of transferred component
(Pa m3 mol 1)
2
J average flux (mol m 2 s 1)
J comsol flux through the gas–liquid interface as obtained
by COSMOL (mol m 2 s 1)
1 J no reaction average flux in case of no chemical reaction
0 5 10 15 20 25 (mol m 2 s 1)
η kr εp τ [−] J reaction average flux in the presence of a chemical reaction
(mol m 2 s 1)
Fig. 11. Enhancement factor as a function of kτ ¼ ηkr εp τ for all studied cases. The symbols J flux (mol m 2 s 1)
correspond to the legend entries given in Table 2, the solid line corresponds to Eq. (19). (For k effective reaction rate coefficient (s 1)
interpretation of the references to color in this figure caption, the reader is referred to the
web version of this paper.)
kr intrinsic reaction rate coefficient (s 1)
kgl agl volumetric gas–liquid mass transfer coefficient (s 1)
kls als volumetric liquid–solid mass transfer coefficient (s 1)
L depth of computational domain (m)
! normal vector (–)
n
np number of particles in computational domain (–)
np;x number of particles in the x-direction of the com-
putational domain (–)
np;y number of particles in the y-direction of the com-
putational domain (–)
np;z number of particles in the z-direction of the com-
putational domain (–)
pA partial pressure (Pa)
R retention factor (–)
Rp particle radius (m)
RAv volumetric reaction rate (mol m 3 s 1)
t time (s)
Vd volume of the computational domain (m3)
Vp volume of a particle (m3)
W width of computational domain (m)
X uniformly distributed random variable (m)
xp weight fraction of particles (–)
xr x-coordinate of randomly distributed particle (m)
xi;j;k x-coordinate of hexagonal distributed particle (m)
Fig. 12. Enhancement factor ðE0 Þ according to Eq. (20) as a function of ηkr εp τ. The
yr y-coordinate of randomly distributed particle (m)
figure shows the solutions for E0 for various values of DDsl along with the data
obtained from the numerical simulations. (For interpretation of the references to
yi;j;k y-coordinate of hexagonal distributed particle (m)
color in this figure caption, the reader is referred to the web version of this paper.) z spatial coordinate (m)
zr z-coordinate of randomly distributed particle (m)
zi;j;k z-coordinate of hexagonal distributed particle (m)
of DDsl for E0 . Therefore, we conclude that the homogeneous model
can be used to predict the enhancement of the mass transfer due Greek symbols
to the presence of catalytic particles in a relative easy manner
using Eqs. (19) and (20) without the need to resort to elaborate δ minimum distance between particles (m)
simulations. δgp minimum distance between gas–liquid interface
and the shell of the nearest particle (m)
Nomenclature εp particle volume fraction (–)
ϕ Thiele modulus (–)
Roman symbols η effectiveness factor (–)
A area (m ) 2 ρl liquid phase density (kg m 3)
C concentration (mol m 3) ρp bulk density of a particle (kg m 3)
P.W.A.M. Wenmakers et al. / Chemical Engineering Science 145 (2016) 233–244 243
τ contact time (s) The time-averaged flux at the gas–liquid interface in case of a
θ dimensionless parameter for calculation of sus- reaction now becomes:
pension diffusion coefficient (–) 0sffiffiffiffiffi 1
Z pffiffiffiffiffi expð ktÞ
1 τ k
J ¼ C D @ erf ð kt Þ þ pffiffiffiffiffiffiffiffiffiffi A dt ðA:11Þ
τ 0 0 s Ds π Ds t
Acknowledgments 0sffiffiffiffiffi 1
Z τ pffiffiffiffiffi Z τ
C 0 Ds k expð ktÞ A
J ¼ @ erf ð kt Þ dt þ p ffiffiffiffiffiffiffiffiffiffi dt ðA:12Þ
Patrick Wenmakers and Niels Deen thank Hans Kuipers and τ Ds 0 0 π Ds t
Johan Hoorn for making it possible to do this work in the context
2sffiffiffiffiffi pffiffiffiffiffi 3
of a research exchange programme between DSM and TU pffiffiffiffiffi τ expð kτÞ erf ð kτ Þ
C 0 Ds k 1
Eindhoven. J ¼ 4 τ erfð kτÞ þ pffiffiffiffiffiffiffiffiffi þ pffiffiffiffiffiffiffiffi 5
τ Ds 2k π kτ kDs
ðA:13Þ
Appendix A. Analytical solution 2 qffiffiffiffi pffiffiffiffiffi 3
pffiffiffiffiffiffiffiffi 1
pffiffiffiffiffi expð kτÞ Ds
erfð kτÞ
J ¼ C 0 4 kDs 5
k
1 erf ð kτÞ þ pffiffiffiffiffiffiffiffiffi þ
A.1. Enhancement factor 2kτ π kτ τ
A similar reasoning and approach can be applied to Eq. (20), Ramachandran, P.A., 2007. Gas absorption in slurries containing fine particles:
which after rewriting reads: review of models and recent advances. Ind. Eng. Chem. Res. 46 (10), 3137–3152.
sffiffiffiffiffi Ruthiya, K.C., 2005. Mass Transfer and Hydrodynamics in Catalytic Slurry Reactors
pffiffiffiffiffi expð kτÞ
1pffiffiffiffi Ds pffiffiffiffiffi
(Ph.D. thesis), Technische Universiteit Eindhoven.
1
E0 ¼ π kτ þ pffiffiffiffiffi erfð kτÞ þ pffiffiffiffi ðA:25Þ Ruthiya, K.C., Van Der Schaaf, J., Kuster, B.F.M., Schouten, J.C., 2004. Modeling the
2 Dl 2 kτ π effect of particle-to-bubble adhesion on mass transport and reaction rate in a
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sffiffiffiffiffi describe mass-transfer enhancement by catalyst particles adhering to a gas-
liquid interface. Ind. Eng. Chem. Res. 44 (16), 6123–6140.
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