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ISBN: 81-308-0026-8
Abstract
Direct methanol fuel cells (DMFCs) have a
continuous supply of methanol as the fuel to the anode
and convert chemical energy directly into electrical
energy with high-energy density and low emission of
pollutants. DMFCs are about to come of age as power
sources for electric vehicle, transport applications
and portable electronic devices including lap tops,
cell phone power packs, generators, and other powerhungry products. One of the major challenges in the
commercialization of DMFCs is the high cost of noble
metal-based electrocatalysts and state-of-the-art
Correspondence/Reprint request: Dr. Bing Joe Hwang, Nanoelectrochemistry Laboratory, Department of
Chemical Engineering, National Taiwan University of Science and Technology, Taipei 106, Taiwan, Republic
of China. E-mail: bjh@ch.ntust.edu.tw
Nafion membranes. In this regard major research efforts have been directed
towards finding innovative materials with attributes such as decreased catalyst
loadings, optimum fuel and proton access to the active sites, electronic
continuity in the carbon supports and low methanol permeability in the proton
exchange membranes. In this chapter we described the recent progress
including our own work in search and development of innovative
electrocatalysts both for methanol oxidation reaction (MOR) and oxygen
reduction reaction (ORR), carbon supports, and proton exchange membranes
alternative to Nafion.
1. Introduction
Direct methanol fuel cells (DMFCs) are promising energy sources for
vehicle and portable devices because of its high-energy conversion efficiency,
low-to-zero pollutant emission, methanol fuel availability, high-energy density
of the fuel (6000 Wh/kg), and low operating temperatures (60 to 100 oC) [13].
When compared to the emissions from conventional internal-combustionengined vehicles (ICEVs), the emissions from DMFCs at an operating
temperature range from 60 to 80 oC are significantly lower. Apart from the
principle emitters such as CO2 and H2O traces of formaldehyde can also be
found. However, due to the inherent higher efficiency of DMFCs, the extent of
carbon monoxide emission is substantially lower than that from ICEVs [4].
With the strict environmental laws and due to the increased concerns on the
consequences of fossil fuel usage in power generation and propulsion of
vehicles, much efforts have been focused on the development of powerful,
clean and finely distributed power generation and development of DMFCs
comes under this aim. Despite the significant progress, DMFCs still suffer
from many obstacles such as low power density, which has been attributed to
the poor kinetics of both anode [5], and cathode [6], high flux of
water/methanol across membranes [7], and mixed potential at cathode [8].
These phenomena lead to high overpotentials involving methanol cross-over
overpotential, activation overpotential, and concentration overpotential at both
the anode and the cathode sides and, hence, reduction in cell voltage. Other
important constraints are the high cost of noble metal catalysts and
perfluorosulfonic membranes and higher production costs of the various
components of the device.
A great deal of effort has been devoted over the years to the development
of innovative materials for DMFCs and in this chapter; we describe recent
progress in the development of carbon supports, electrocatalysts both for
methanol oxidation reaction (MOR) and oxygen reduction reaction (ORR), and
proton exchange membranes alternative to state-of-the art Nafion membrane
for DMFCs. Before discussing these issues in details we will discuss briefly
(1)
(2)
Reactions (1) and (2) can be combined to give the overall reaction:
CH3OH + 3/2O2 CO2 + 2H2O [Ecell = 1.21 V]
(3)
Figure 1. Schematic drawing and principle of a DMFC single cell depicting H+, H2O
and CH3OH transport through the proton exchange membrane (PEM).
(4)
Pt (CH3OH)ads Pt (CH3O)ads + H+ + e
(5a)
Pt (CH3O)ads Pt (CH2O)ads + H+ + e
(5b)
Pt (CH2O)ads Pt (CHO)ads + H+ + e
(5c)
Pt (CHO)ads Pt (CO)ads + H+ + e
(5d)
On the pure Pt surface water dissociation will occur only at higher anodic
overpotentials to form Pt(OH)ads species (equation 6):
Pt + H2O Pt(OH)ads + H+ + e
(6)
The last step is the reaction of PtOH species with Pt-adsorbed CO to give
carbon dioxide (equation 7):
Pt (CO)ads + Pt(OH)ads 2Pt + CO2 + H+ + e
(7)
(8)
M(H2O)ads M(OH)ads + H+ + e
Pt (CO)ads + M(OH)ads Pt + M + CO2 + H+ + e
(9)
(10)
(11)
(12)
Platinum has long been the best electrocatalyst for ORR, and oxygen
reduction over platinum and other Pt bimetallic surfaces has been reviewed
recently [3032]. As discussed in these reviews, over the three low-index
(100), (111), and (110) platinum surfaces in aqueous perchloric and sulphuric
acid, the complete four-electron reduction to water can be observed. Two
electron reduction to hydrogen peroxide occurs on the Pt (111) surface in the
hydrogen adsorption region which is an evident of surface site blocking by
H(ads). Equally OH(ads), which begins forming from water decomposition at
about 0.6 V on platinum electrodes, is also believed to inhibit oxygen
reduction by blocking surface sites, and it may contribute to the need to
operate oxygen electrodes at several millivolts relative to the 1.23 V reversible
potential on the standard hydrogen scale.
On Pt electrode surface the adsorption and reduction of O2 via fourelectron reduction pathway follows the steps (equation 13a13d):
PtO2 + H+ + e PtOOH
(13a)
PtOOH + H+ + e
(13b)
PtO + H2O
PtO + H+ + e PtOH
(13c)
PtOH + H+ + e PtOH2
(13d)
Sidik and Anderson have applied density functional theory to study the
four-electron reduction mechanism of O2 on platinum in aqueous acidic
electrolytes [33]. Their studies suggest that the first electron transfer step
(equation 13a) is the rate determining step. They have calculated the activation
energy for the rate determining step which is of about 0.60 eV at 1.23 V and
close to the experimental value of 0.44 eV on Pt (111) in H2SO4.
In the two-electron reduction pathway the O2 reduction follows the steps
(equation 14a14b):
PtO2 + H+ + e PtOOH
(14a)
PtOOH + H+ + e Pt(OHOH)ads
(14b)
(14c)
Pt(OH) + H+ + e PtOH2
(14d)
supports in a PEMFC. The use of carbon nanotubes and the resulting feasible
electronic pathway eliminate the problem of isolation of carbon particles from
the electrode support due to the presence of Nafion used in conventional
PEMFC strategies. This approach will improve the Pt utilization. The authors
have reported that Pt catalyst loadings can be achievable up to 0.2 mg cm2
with the obtained MWNT-carbon.
Girishkumar et al have demonstrated a method to obtain films of varying
amounts of single-walled carbon nano tubes (SWCNTs) on optically
transparent electrode (OTE) surfaces using electrophoretic deposition.
Platinum is electrodeposited on the SWCNT-OTE and the electrodes are
studied for methanol oxidation as well as for oxygen reduction [53]. The high
surface area and porosity of the SWCNT-OTE films enable them to use
relatively small amounts of platinum and yet obtain excellent currents.
Multiwalled carbon nanotube-supported Pt (Pt/MWNT) nanocomposites
were prepared by the aqueous solution reduction of a Pt salt (HCHO
reduction), Pt/MWNT (A) and the reduction of a Pt ion salt in ethylene glycol
solution, Pt/MWNT (B) by Liu et al [48]. The Pt/MWNT catalyst prepared by
the EG method has a high and homogeneous dispersion of spherical Pt metal
particles with a narrow particle-size distribution and the Pt particle size is in
the range of 25 nm. From their results it is found that the surface chemical
modifications of MWNTs and water content in EG solvent are the key factors
in depositing Pt particles on MWNTs. In the case of the direct methanol fuel
cell (DMFC) test, the Pt/MWNT catalyst prepared by EG reduction is slightly
superior to the catalyst prepared by aqueous reduction and displays
significantly higher performance than the Pt/XC-72 catalyst. The limited
current density and maximum power density of the single cell with the
synthesized Pt/MWNTs and Pt/XC-72 decrease in the following order:
Pt/MWNT (B) > Pt/MWNT (A) > Pt/Carbon XC-72. The authors have
concluded that by using MWNTs as supports the lower platinum loadings (1.0
mg/cm2) can be achieved. Also by lowering the agglomeration degree of metal
particles in the Pt/MWNT (B) catalyst, the reactants easy access to the
catalytic active sites, which would help to enhance the mass transport in the
cell system further, can be improved. These differences in catalytic
performance between the MWNT-supported or the carbon black XC-72supported catalysts are attributed to a greater dispersion of the supported Pt
particles when the EG method is used, in contrast to aqueous HCHO reduction
and to possible unique structural and higher electrical properties when
contrasting MWNTs to carbon black XC-72 as a support.
Liu et al have provided a method to deposit Pt nanoclusters of about 15
nm in diameter on MWCNTs by electroless deposition [49]. The MWCNTs
are first pretreated with a solution of SnCl2/HCl and next placed in a platinum
10
electroless plating solution and MWCNTs with this plating showed higher
electrocatalytic activity for oxygen reduction in a single stack PEM fuel cell.
Rajesh et al have demonstrated a method to place the catalyst on the inside
of the CNTs. Their approach involves; first the CNTs are immersed in
hexachloroplatinic acid and ruthenium chloride [54]. Then the incorporated
metal ions are reduced to the corresponding metals by exposure in hydrogen
gas at 823 K which yields a Pt or PtRu nanocluster loaded on CNT. In order
to load the inside of the CNTs with WO3, which later will be bonded to Pt for
lower activation energy in DMFCs; the CNT is immersed in peroxo tungstic
acid. This immersion allows the peroxo-tungstic acid to penetrate inside the
pores of the CNTs. Finally, the WO3/CNT structure is immersed in
hexachloroplatinic acid, dried, and reduced with hydrogen gas at 623 K. Thus
the result is a CNT with platinum tungsten-oxide nanoclusters inside.
The literature reports described in this section on CNTs as supports to
noble metal particles have reached almost similar conclusions. Most of the
researchers have concluded that the high electrocatalytic activities have been
attributed to the: (i) high and homogeneous distribution of noble metal
particles on CNTs, (ii) unique structural and high electrical properties, (iii)
larger surface area provided by the CNT architecture, (iv) specific interaction
between Pt and CNTs, and (iv) enhanced mass transport via facile access of
reactants to the catalytically active site in the fuel cell operation.
11
12
13
catalyst showed 79% high maximum power density than that of the E-TEK and
Vulcan carbon-supported catalysts. The enhanced catalytic activity found with
POBPC materials is attributed to their high surface areas and larger pore
volumes of porous carbons which allow greater degree of catalyst dispersion.
Due to the three-dimensionally interconnected macroscale and mesoscale
bimodal porosity provides an open-highway network around the active
catalyst for the facile diffusion of fuels and products to and from the catalyst.
In the case of Vulcan carbon with its randomly distributed pores of varying
size, respectively which may make fuel and product diffusion less efficient.
Some of these carbon materials discussed above when applied as supports
exhibit promising activities towards electrochemical reactions in DMFCs
(Table 1).
Table 1. Summary of carbon supports for DMFCs under development.
3.2. Electrocatalysts
3.2.1. Electrocatalysts for methanol oxidation reaction
Electro-oxidation of methanol occurring at anode of DMFCs received
great attention of both the academic and industrial researchers and a significant
number of investigations have been carried out [65, 44]. To establish the best
electrocatalyst composition, methanol oxidation on smooth electrode surfaces
has been carried out in half-cell configuration. Electrochemical investigations
coupled with spectroscopic techniques have been used to understand the
oxidation mechanism and to find out the nature of the adsorbed species on the
14
electrode surfaces. Platinum is considered to be the best material for both the
absorption and dehydrogenation of methanol [10]. The progressive
dehydrogenation of the adsorbed methanol produce either linear or bridgebonded carbon monoxide (CO) species which are strongly adsorbs on Pt
surface (COads). COads species will poison the Pt electrode by blocking the
active sites for methanol absorption and it is a significant impediment to the
development of DMFCs [66]. Alloys with Pt have been sought as a means of
enhancing the efficiency of methanol oxidation and this alloying route has
achieved most successful results so far. PtRu was among the first binary
systems to be studied and it remains the most effective [15, 67]. Alloying Pt
with Sn also showed promising results for methanol oxidation and CO
removal.
15
16
Figure 2. TEM image of PtRu/C catalyst prepared by a Nafion-stabilized alcoholreduction method [91].
Recently, Nuzzo and Shapley have reported that the PtRu carbonyl
cluster complexes, PtRu5C(CO)16 and Pt2Ru4(CO)16 can serve as single-source
molecular precursors for the preparation of PtRu5 and PtRu2/C nanocomposites
[9395]. They prepared carbon-supported PtRu nanoparticles with a 1:5
Pt:Ru composition by the reductive condensation of a carbon-supported
molecular cluster precursor PtRu5C(CO)16. During the H2 reduction process at
473 K the PtRu nanoparticles form a disordered structure in which Pt is found
preferentially at the core of the condensing particle. After further hightemperature treatment to 673 K the nanoparticles adopt an inverted structure in
which Pt appears preferentially at the surface of the bimetallic nanoparticle.
With this process it is possible to prepare the PtRu nanoparticles with an
average diameter of 1.5 nm.
Lukehart et al have described the preparation of a Pt1-Ru1/carbon
nanocomposite
using
(-C2H4)(Cl)Pt(-Cl)2-Ru(Cl)(3:3-2,7dimethyloctadienediyl) as a noncluster, 1:1 Pt:Ru bimetallic molecular
precursor [57]. Vulcan carbon (Cabot Corporation, XC72R) serves as the
traditional carbon powder support. Microwave dielectric loss heating permits
rapid conversion of precursor/carbon composites to the desired
nanocomposites under appropriate conditions. This method can produce the
PtRu nanocomposites with arbitrary total metal loadings of 16 and 50 wt%
having metal alloy nanocrystals of 3.4 and 5.4 nm average diameters,
respectively. The PtRu nanocomposites with 16 wt% metal loading shows
catalytic performance comparable to that of related commercial catalysts
17
18
electronic states of Pt, which affects both the activation of methanol CH bond
and weakening of CO binding to Pt facilitates the CO2 removal. The increase
in Pt d-band vacancies upon alloying with Ru as studied by X-ray absorption
spectroscopy supports the ligand effect of Ru on Pt [100]. Increase in Pt dband vacancies upon alloying with Ru can be evidenced in PtRu catalysts
from the increase in white line area of Pt absorption edge from the X-ray
absorption near-edge spectra (Figure 3).
Figure 3. Pt LIII-edge XANES spectra of a PtRu catalyst prepared by Nafionstabilized alcohol-reduction method (solid line) and a Pt foil (line with triangles).
19
(1)
(2)
20
The parameters Pobserved, Robserved, Prandom, and Rrandom are defined as follows. The
parameter Pobserved can be defined as a ratio of the scattering atoms B
coordination number around absorbing A atoms (NAB) to the total
coordination number of absorbing atoms (NAi), (Pobserved =NAB/NAi).
Similarly, Robserved can be defined as a ratio of the scattering atoms A
coordination number around absorbing B atoms (NBA) to the total
coordination number of absorbing atoms (NBi), (Robserved = NBA/NBi).
Whereas, Prandom and Rrandom can be taken as 0.5 for perfect alloyed bimetallic
NPs if the atomic ratio of A and B is 1:1. This value can be achieved by
assuming NAA = NAB and NBB = NBA which is generally true for perfect
alloyed bimetallic NPs. In a similar way Prandom can be taken as 0.67 and 0.8
for 1:2 and 1:4 bimetallic NPs respectively. The parameter Rrandom can be taken
as 0.33 and 0.2 for 1:2 and 1:4 bimetallic NPs respectively.
It is possible to construct the structural models emphasizing the atomic
distribution in the bimetallic NPs with the knowledge of the NAi, NBi, JA
and JB values derived from XAS. With the help of extent of alloying values
and structural parameters extracted from EXAFS it is possible to predict the
structure models of PtRu/C catalysts. We have calculated the alloying extent
of Pt (JPt) and Ru (JRu) for commercial 30 wt% PtRu/C catalysts.
In case of JM 30 catalyst the coordination numbers of Pt and Ru atoms
around the Pt atom are found to be 5.6 0.3 and 1.4 0.1, respectively, and
the total coordination number NPti is 7.0. The coordination numbers of Ru
and Pt atoms around the Ru atom are determined as 3.4 0.2 and 2.2 0.3,
respectively, and the total coordination number NRui calculated as 5.6. From
these values Pobserved and Robserved determined as 0.20 and 0.39, respectively, and
JPt and JRu values are calculated as 40 and 78%, respectively. For E-TEK 30
catalyst we have calculated the coordination numbers of Pt and Ru atoms
around the Pt atom as 6.2 0.3 and 0.9 0.1, respectively, and NPti as 7.1;
the coordination numbers of Ru and Pt atoms around the Ru atom are
determined as 3.7 0.2 and 1.2 0.2, respectively, and the NRui as 4.9. The
other two structural parameters Pobserved and Robserved in the case of E-TEK 30
are calculated as 0.13 and 0.24, respectively, and the JPt and JRu values are
calculated as 26 and 48%, respectively. It is clear from the structural
coordination parameter values of both the catalysts that NPti > NRui and JRu
> JPt, which indicates that the catalysts adopt a Pt rich in core and Ru rich in
shell structure. A schematic representation of the catalyst structures is given in
figure 4.
From the quantitative extent of alloying values, we can see that in both the
catalysts considerable amount of Ru is segregated on the shell layer but the
extent of segregation of Ru is higher in E-TEK 30 when compared to the JM
30. The increased value of JRu in JM 30 catalyst indicates that most of the Ru is
involved in alloying and hence less segregation of Ru in the shell whereas in
21
Figure 4. Structural models deduced for JM 30 (a), and E-TEK 30 PtRu/C catalysts
(b) based on XAS parameters.
the case of ETEK 30 catalyst lesser extent of Ru is involved in the alloying and
considerable extent of segregation of Ru can be expected in the shell region.
The segregation of Ru in the case of ETEK 30 in part may be responsible for
its lower methanol oxidation activity compared to JM 30. Recent infrared
measurements on the PtRu alloy particle electrodes indicates two modes of
adsorbed CO vibrations related to both Pt and Ru domains present on the
surface supports the surface segregation of Ru in commercial catalysts [106].
The XAS results support the Pt-rich core and Ru rich shell structure for
commercial carbon-supported PtRu catalysts. Increase in JPt and JRu values in
JM 30 compared to E-TEK 30 indicates that the atomic distribution of Pt and
Ru atoms are much facilitated. Increase in atomic distribution can be taken as a
measure for enhanced homogeneity.
22
23
24
25
Pt3Ni > Pt. The catalytic enhancement of the ORR on Pt3Ni and Pt3Co vs. Pt is
attributed to the inhibition of PtOHad formation on Pt sites surrounded by
oxide-covered Ni and Co atoms beyond 0.8 V. Kinetic parameters for the
ORR and the production of H2O2 on the Pt3Ni, Pt3Co, and Pt-skin alloys are
the same as the pure Pt. The reaction order (m) was found to be one. The Tafel
slope (90110 mV/dec) and the activation energy (20 to 25 kJ/mol) discerned
for pure Pt is almost the same with values obtained for Pt3Ni and Pt3Co
bimetallic surfaces. The fact that the same kinetic parameters are assessed from
the analysis of the ORR data on all three surfaces implies that the reaction
mechanism on Pt3Ni and Pt3Co alloy surfaces is the same as on proposed for
pure Pt, i.e., a series 4 e reduction pathway.
Very recently, platinum monolayers supported on Au (111), Rh (111), Pd
(111), Ru (001), and Ir (111) surfaces in HClO4 solutions have been studied as
ORR catalysts [178]. The experimentally measured electrocatalytic activity of
platinum monolayers for the ORR shows a volcano-type dependence on the
centre of their d-bands as determined by density functional theory (DFT)
calculations. The platinum monolayer supported on Pd(111) (PtML/Pd(111)) is
at the top of the volcano curve and shows improved ORR activity over pure Pt
(111). They have demonstrated this behavior by two opposite trends: while a
higher lying d-band center tends to facilitate OO bond breaking, a lower lying
one tends to facilitate bond formation (e.g., hydrogen addition).
In an another study Adzic group have demonstrated the kinetics of ORR in
acid solutions on Pt monolayers deposited on a Pd (111) surface and on
carbon-supported Pd nanoparticles using the rotating ring-disk electrode
(RRDE) technique [179]. The kinetics of O2 reduction shows a significant
enhancement at Pt monolayers on Pd (111) and Pd nanoparticle surfaces in
comparison with the reaction on Pt (111) and Pt nanoparticles. They have
suggested four-electron reduction mechanism for both the surfaces. The
observed increase in the catalytic activity of Pt monolayer surfaces compared
with Pt bulk and nanoparticle electrodes may reflect decreased formation of
PtOH.
Development of Pt-alloys and Pt monolayers on Pd electrocatalysts are
showing promising results towards oxygen reduction reaction. These catalysts
enable a reduction of ORR overpotential losses by approximately 50 mV and a
summary of these catalysts is shown in Table 3. The most important points to
be considered for the development of ORR catalysts are:
(i)
26
(ii)
(iii)
(iv)
27
channels [184]. Proton conductance occurs through the ionic channels of the
membranes [185]; these channels are formed by micro- or nanophase
separation between the hydrophilic proton exchange sites and the hydrophobic
domain. The Nafion membranes assure high proton conductivity ( 102
S.cm1) and high chemical stability. However during the DMFC operation the
unreacted methanol at the anode can diffuse through the membrane and utilizes
the cathode Pt sites for the direct reaction between methanol and oxygen,
generating a mixed potential that reduces the cell voltage [186, 187]. Possible
ways to mitigate this problem include using the thick Nafion 117 membranes
(1100 EW, 7 mil ~ 178 m thick) and supplying the anode with dilute
methanol, for example, 1 M or less to reduce the methanol crossover. However
it is pointed out that the use of dilute methanol feed increases the systems
complexity and reduces the energy density of the fuel, while the use of thick
Nafion membrane increases the resistive losses of the cell [188]. Another way
to overcome the methanol cross-over problem is to develop new polymer
systems, or modify the existing membranes in order to achieve high ionic
conductivity, low permeability to DMFC reactants, long-term stability under
operating conditions and low cost [189].
There have been several attempts to explore non-perfluorinated polymers
without the disadvantages of Nafion [190195]. Most of the works discussed
about the incorporation of inorganic acid groups in to the basic polymer
matrices like poly (sulfones)s, poly (ether ether ketone)s, poly (imides),
polybenzimidazole, and polyacrylamide etc. The cost of these membranes is
comparatively lower than the state-of-the-art Nafion membranes and
properties are improved [196, 197]. Review articles dealing with the
development of polymer-based proton conductors [198201], organic
inorganic composites [202], polymer electrolyte membranes for fuel cells
operating above 100 oC [203], and alternative polymer systems for proton
exchange membranes (PEMs) [188] have been recently published.
The common requirements for proton exchange membranes include (1)
high proton conductivity, (2) low electronic conductivity, (3) chemical
stability, (4) thermal stability, (5) good mechanical properties in both the dry
and hydrated states, (6) low water drag through diffusion and electro-osmosis,
and (7) reasonable cost. In order to select the proper membrane for DMFC
applications the most important parameters need to be characterized are proton
conductivity, methanol permeability, and water swelling. The proton
conductivity of the membranes can be evaluated by impedance spectroscopy
[204, 205]. The methanol permeability can be estimated by pervaporation
[206, 207] and diffusion cell experiments [208, 209]. Water swelling which
gives a measure of the water solubility in the membranes is usually evaluated
using batch experiments in liquid solutions at room temperature [210].
28
29
30
31
32
33
5. Conclusions
There is still a clear need for the synthesis and complete characterization
of new carbon supports, electrocatalysts and proton exchange membrane
materials for DMFCs. Herein we have reviewed the recent progress achieved
in the development of materials for DMFCs. In the search for carbon materials,
focus has been made in attaining well-ordered porosity, high surface area, and
good mechanical strengths. In recent years, mesostructured carbon materials
are emerging as promising supports for fuel cell catalysts because the pore
structure of the carbons can be tailored as a function of the silica that is used as
template. Other important factors to be considered in the development of
carbon materials are dispersion effect, and electronic conductivity. Regarding
the electrocatalysts stress should be made on the evaluation of better catalysts
other than PtRu catalysts, need to achieve higher loadings on carbon supports,
and care should be taken in comparing the catalytic activities of different
electrocatalysts. It is difficulty to compare the activity of different
electrocatalysts appeared in the literature as there is no standard evaluation
method available. Active surface area normalization procedures are beneficial
in this regard. Methodologies are required to determine the extent of alloying
and atomic distribution in fuel cell catalysts as these properties have profound
influence on the surface properties which affect the catalytic activity,
34
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