Author: rusty

In order to reduce our carbon emissions and look towards building a sustainable future for ourselves, the EU has adopted new HGV emission targets that are designed to meet carbon-neutrality by 2050.

It has been reported that heavy duty vehicles are responsible for around a fifth of CO2 emissions from road transport in the EU, and 6% of EU carbon emissions overall. Therefore if we want to achieve carbon-neutrality then the entire transport sector needs to change the way it operates.

One solution to help cut emissions is to replace fossil fuels with hydrogen fuel. Many people are citing hydrogen as the fuel of the future, predicting that 50,000 hydrogen-powered buses and 350,000 hydrogen-powered trucks will be on the motorways by 2030.

What are the government aims?

The objective is that by 2030 truck CO2 emissions will be cut by a third from 2019 levels with the help from green hydrogen fuel. Governments are offering up to 75% lower road tolls for fuel efficient vehicles, and introducing higher taxes and diesel ban threats on those that are not eco friendly. In addition they are working with suppliers to help fund innovative climate projects, and in the UK electric trucks and hydrogen-powered buses are set to secure nearly 10,000 UK jobs and save 45 million tonnes of carbon emissions.

As a result, a lot of leading truck-makers are investing heavily in greener fuel, and globally, hydrogen fuel cell trucks are seen as a key solution for running clean commercial vehicles.

What are hydrogen powered vehicles?

Hydrogen powered vehicles work in a similar way to gasoline powered cars, where energy is released by creating a chemical reaction. However, unlike gasoline powered cars they do not emit any vehicle emissions other than water vapour - therefore can help us secure a greener future.

There are two ways in which hydrogen powered cars can create electricity: hydrogen fuel cells or hydrogen powered engines. Fuel cell trucks are filled with hydrogen from the vehicle’s fuel tank, mixing hydrogen with oxygen to create H2O in an electrochemical process. Whereas a hydrogen-powered engines uses combustion as its chemical reaction - burning hydrogen instead of gasoline and converting the hydrogen into mechanical energy.

Are hydrogen powered trucks better than electric?

Hydrogen powered trucks are regarded as the best solution for long haul drivers, particularly vehicles travelling beyond the urban built up areas. This is largely because they overcome some of the limitations that electric vehicles face:

Hydrogen powered trucks

Electric vehicles

Electricity from a fuel cell

Electricity from a battery

Great for the environment

Great for the environment

Short refuelling time

Long refuelling time

Suitable for long distances

Better suited for short distances

Can pull heavier loads uphill 

Struggles with heavier loads uphill

The main characteristics that distinguish hydrogen from electric is the short refuelling time, being able to go long distances, and pulling heavier loads uphill is sometimes a requirement of a job. It would not be practical for a truck fleet going across country to make regular stops to charge and burden the local electricity grid as it does so. That is why hydrogen is the better solution for vehicles such as: trucks, lorries, vans, refuse vehicles, class 8 and HGV, tractors and forklifts.

The pros and cons of hydrogen powered trucks and lorries The pros

There are a lot of attractive characteristics of hydrogen powered vehicles that make them the perfect solution:

1. No vehicles emissions other than water vapor
2. Hydrogen is abundant and can be made from renewable energy
3. Short refuelling times
4. Long usage time
5. Perfect for heavy loads
6. Better fuel economy
7. No engine noise or visual pollution

The Cons

However, hydrogen fuel cells also come with a set of challenges to overcome in order to be effective, in order for it to work it needs to be green hydrogen:

1. The technology is expensive at the moment so investment is required
2. The majority of energy used in the hydrogen extraction process currently comes from non-renewable sources
3. Requires extremely high-pressure, on-board hydrogen storage
4. Few places to refuel

How Luxfer can help

Luxfer Gas Cylinders are determined to be part of the change for a better future, setting themselves a 2025 goal to reduce CO2 emissions by 20%. One of the ways in which Luxfer can help protect the environment is by getting involved in projects involving hydrogen fuel.

Luxfer can help overcome some of the temporary limitations of hydrogen fuel by:

1. Working with OEMS to make efficiencies
2. Encouraging other companies to invest in renewable energy such as wave, solar, biomass, geothermal and wind
3. Continue to develop gas cylinders for on-board hydrogen storage, such as the 400. Luxfer G-storTM H2 hydrogen cylinders
4. Help develop the framework and pipework for seamless integration into Hydrogen powered vehicles, all adhering to stringent quality and safety regulations

One of the challenges hydrogen fuel faces is being able to store it safely. Luxfer works with many commercial vehicle managers around the world to provide them with hydrogen storage cylinders and complete fuel storage solutions, taking responsibility for safety standards and certification. Recently, Luxfer was commissioned by Hyundai to help create the first green commercial truck fleet in history.

Hyundai and Luxfer partnership

Hyundai were one of the first to commit to hydrogen as a replacement energy to fossil fuels. They have already invested heavily in it, planning to put 1,600 hydrogen trucks on the roads in Switzerland by 2025. The chief executive of Hyundai Hydrogen Mobility states that it isn’t enough to produce just one truck “we have to change the entire ecosystem”.

The multi-million-pound project integrating hydrogen fuel cell technology has recently put 50 hydrogen-powered lorries into service for a supermarket chain in Switzerland. The Hyundai Xcient Fuel-Cell trucks are the first green commercial fleet to hit the roads, and will transport supermarket deliveries across the country.

They commissioned Luxfer to provide the knowledge of a complete fuel system in order to bring their ideas to life. Dr. Mark Lawday, director at Luxfer Gas Cylinders explains: “Switzerland is an ideal market for hydrogen-powered trucks, thanks in part because the country generates more than half of its energy from hydropower, so if this can be used to generate the hydrogen then it completely eliminates emissions.

"Each hydrogen truck features a 190 kilowatt fuel cell comprised of seven high-pressure tanks holding around 35kg of hydrogen. This provides a long distance range of about 400km before refuelling is required, which far surpasses the capabilities of vehicles powered by electric.”

When speaking to drivers they commented that there was no need to change up their driving style, instead being more than impressed with the acceleration and quiet engine.

Since development began on the landmark project in Feb 2019, the Luxfer Hyundai design team have developed the framework and pipework for seamless integration into Hyundai’s vehicles, all adhering to stringent quality and safety regulations.

The future of hydrogen fuel cell trucks

With over 100,000 fuel cylinders already in use on over 18,000 vehicles around the world, it’s off to a promising start. The Hydrogen Council estimates there will be 50,000 hydrogen-powered buses and 350,000 hydrogen-powered trucks on the world’s roads by 2030.

Luxfer anticipates that hydrogen fuel cell trucks will become increasingly attractive for heavy goods transportation, as the cost of producing clean fuel drops and greener alternatives to diesel are supported with funding. In fact, Luxfer recently expanded its hydrogen facility in Nottingham, to meet the increased demand for alternative fuel solutions for the transport industry and our collective drive for a greener future. We're dedicated to continue innovating our hydrogen fuel systems to reduce costs, improve efficiency and make storage safe and easy for all users.

With the increasing impact that the climate crisis has proven to have on our world, the demand to build a more sustainable future and to reduce our carbon footprint has grown significantly.

By switching to hydrogen fuel cells on buses and coaches, we can significantly reduce the carbon footprint of the transportation industry, which will empower nations and local authorities to meet their environmental goals.

Hydrogen fuel systems replace petrol and diesel engines to create automotive power while only producing water vapour as a by-product.

The rail system

One of the areas in which there is a potential to change and help cut emissions is the rail system. Hydrogen-powered trains could be the answer to decarbonising a major part of the UK’s emissions, and doing so would be a cheaper alternative as well.

According to an assessment of 20 lines in Britain, electrifying one kilometer of track can cost £750,000 to £1m. Hydrogen-powered trains are a lot less expensive because they can be created by retrofitting existing diesel trains. This would be especially beneficial in rural areas where the distance to cover is greater but the passengers are fewer, as this would justify the expense.

The UK already has 42% of its route electrified, which means trains that run on those tracks are ready to become zero-carbon, by relying mainly on electricity and the remaining of time, on hydrogen. Therefore, no fossil fuels would be used to power those trains. However, 58% of UK track is not yet electrified which means diesel trains are still a necessity.

What are hydrogen trains?

How it works - hydrogen trains work based on a simple power system consisting of hydrogen cylinders, a fuel cell, batteries, and finally, a motor.

The stored hydrogen passes through the fuel cell, where it is split into electrons and protons. The electrons are then forced through a circuit, producing electric charge. This electric charge is then stored in lithium batteries, or sometimes it is sent directly to the motor.

The leftover part of the hydrogen molecule reacts with oxygen and becomes the waste product - water. The train’s hydrogen power system is designed to power the train to the equivalent distance of its diesel equivalent.

The pros and cons of hydrogen trainsThe pros

There are a lot of characteristics of hydrogen powered trains that make them the perfect solution to cutting carbon emissions:

1. No vehicle emissions other than water vapors
2. Hydrogen is abundant and can be made from renewable energy
3. Short refuelling times
4. Their potential as a bi-mode train, meaning they can run on the electrified or conventional lines alike
5. Better fuel economy
6. No engine noise or visual pollution
7. No risk to network wide disruption

The cons

Hydrogen fuel cells also come with a set of challenges to overcome in order to be effective:

1. The technology is expensive at the moment so investment is required
2. The majority of energy used in the hydrogen extraction process currently comes from non-renewable sources
3. Requires extremely high-pressure, on-board hydrogen storage
4. Few places to refuel
5. The hydrogen system currently sits inside a passenger car, which limits the number of people who can get on board in that carriage
6. Hydrogen trains are still dependent on primordial hydrogen and infrastructure at the moment

The future of Hydrogen

Rail operators in England have been given a target to replace diesel trains with ones using cleaner fuel technologies by 2040. We are working with several manufacturers and leasing companies to develop new trains and also to convert mid-life and redundant rail stock to hydrogen-powered locomotives.

The first hydrogen train - The UK’s first hydrogen-powered train was unveiled in June 2019. The HydroFLEX project comprises a former Thameslink electric train retrofitted to run using a hydrogen fuel system. Luxfer’s alternative fuel experts worked in close collaboration with Porterbrook and the University of Birmingham’s Centre for Railway Research, which won the Department for Transport funding to support the concept. The four-cylinder hydrogen solution was developed and assembled at our alternative fuel facility in the UK and in September 2020 the train, with a range of 600 miles, hit the mainline for the first time.

How Luxfer can help

One of the challenges hydrogen fuel faces is being able to store it safely. The structure of our G-Stor H2 cylinders is such that it is impermeable which offers the best safety option for hydrogen gas which may be stored in special compartments within or under the carriage.

At Luxfer, we take pride in giving each of our customers the ability to help reduce pollutants by facilitating innovative new fuel technologies.

We believe that hydrogen fuel cells are the best green alternative to petrol and diesel for trains, giving the equivalent power and performance while dramatically cutting emissions. We offer a wide range of cylinder sizes and are now looking at working with vehicle manufacturers across Europe to develop, design and manufacture bespoke fuel cylinder systems.

In addition, we can provide Bulk Gas Transport modules to provide large quantities of hydrogen to keep refuelling stations supplied.

A greener future

We're excited to be continuing innovating our hydrogen fuel systems to reduce costs, improve efficiency and make storage safe and easy for all users.

These systems will help restore clean air in cities and significantly reduce the carbon footprint of the transport industry. We’re inspired to be part of this ever advancing movement for a greener, happier planet.

By switching to hydrogen fuel cells on buses and coaches, we can significantly reduce the carbon footprint of the transportation industry, which will empower nations and local authorities to meet their environmental goals.

Hydrogen powered buses rival diesel and petrol fuelled buses in terms of performance and range, while massively cutting harmful emissions. Hydrogen fuel systems replace petrol and diesel engines to create automotive power while only producing water vapour as a by-product.

What is a hydrogen fuel cell bus?

Hydrogen powered buses work by converting hydrogen molecules into energy to charge a battery pack which powers an electric motor.

A hydrogen fuel system is made up of the following on-board components:

• Hydrogen cylinders
• Fuel cells
• Battery pack
• Electric motor

Here’s how the system works.

1. The hydrogen is brought from the cylinders into the fuel cells, where the hydrogen molecules are broken down into electrons and protons.
2. In the fuel cells, the protons (hydrogen ions) pass through a membrane, while the electrons are forced around the outside. The only by-product of this process is water vapour.
3. The electrons are passed from the fuel cells to charge the battery pack.
4. The battery pack powers the electric motor, enabling the vehicle to move.

 The efficient design of the system means that significant power can be produced while only harmless water vapour is emitted from the exhaust. This makes the hydrogen fuel system one of the cleanest automotive fuel systems available.

How is hydrogen produced?

While hydrogen powered vehicles are essentially zero emission, the hydrogen production process is not necessarily so. The amount of fossil fuel emissions created by the hydrogen production process depends on the type of process being used.

In 2020, it was reported that 95% of the world’s hydrogen was produced using the steam methane reforming process (SMR). In this method, natural gas reacts with steam at a high temperature to produce hydrogen and carbon monoxide. The carbon monoxide is then passed into a secondary reaction to create more hydrogen and carbon dioxide.

This method requires fossil fuels and can potentially be costly in terms of carbon emissions.

The good news is that there are other, cleaner methods of producing hydrogen, such as the electrolysis of water. This process can be made sustainable - for example, by harnessing electricity from a solar or wind farm - in order to create a zero-emission supply chain.

The goal is to continue to innovate this production process so that all hydrogen production plants are working with net zero emissions in the future.

Are hydrogen buses slower than traditional buses?

Hydrogen fuel cell buses can have the same range and speed as a petrol or diesel powered bus. This isn’t limited to single decker vehicles - this method can also be used to power hydrogen double decker buses. In fact, England’s first fleet of hydrogen powered double deckers was launched in London in June 2021.

On average, a hydrogen bus can travel 350 - 400 miles on a single tank of fuel.

This means that passengers can expect their journey on a hydrogen bus to take no longer than it would on a petrol or diesel powered bus. The journey will likely be more pleasant, too, as the ride is smoother and quieter.

A hydrogen fuel bus can be refuelled quickly and easily on the go. On average, a hydrogen bus takes only 3-5 minutes to refuel. As hydrogen refuelling infrastructure expands, it is becoming increasingly more convenient to refuel hydrogen buses.

Are hydrogen buses safe?

While there are always risks when handling combustible fuels, hydrogen is safe to use for public transportation when guidelines are properly followed.

Petrol and diesel are far more flammable than hydrogen. This is because spilled petrol and diesel pool on the ground, creating a highly flammable surface. Fires caused by the ignition of these fuels can burn at high temperatures for a long time.

Hydrogen, on the other hand, disperses rapidly if spilled, rising up into the air at 72 kilometres per hour. This means that the flammable fuel is quickly dispersed into the atmosphere reducing the chance of it igniting.

If the hydrogen does ignite, it produces flames that generate a low radiant heat and the fire should quickly burn out. This is due to the absence of carbon.

Hydrogen is a colourless, odourless gas, which means it can be hard to spot a spill. However, hydrogen refuelling stations operate strict procedures to prevent accidents, including the use of earthing cables which prevent sparks caused by static electricity.

Buses are also fitted with hydrogen detectors that immediately notify operators should a spill occur.

Overall, hydrogen is considerably safer than petrol and diesel alternatives. Although it is a relatively new fuel source, safety is a high priority in all research and development in this field.

What’s the future of the hydrogen fuel project?

"Hydrogen has an important part to play in the decarbonisation of transport and the reduction in CO2 levels that we need to reach to ensure a net zero future.”

Wrightbus chairman, Jo Bamford.

The Mayor of London, Sadiq Khan, has pledged that from now on all new double decker buses in London will be hydrogen, hybrid or electric. The goal for London is to transform the entire fleet of 9,200 single and double decker buses into zero emission vehicles by 2037.

In March 2021 the UK government announced it will be pouring £54 million into emissions-cutting trucks and buses, with the goal of saving 45 million tonnes of carbon emissions. That’s around the same amount of emissions produced by 1.8 million cars over their lifetimes. The initiative is also set to create nearly 10,000 jobs.

From this budget, £11 million will go to the development of hydrogen buses.

What part does Luxfer play?

Our purpose is to provide bus companies with a cleaner and more efficient alternative to fossil fuels to keep vehicles on the road for longer and reduce operating costs.

We’ve been working closely with manufacturers like Wrightbus to supply hydrogen cylinders for buses. Our collaborative approach saw the launch of the world’s first hydrogen bus in Aberdeen in January 2021.

Hydrogen buses are being introduced in many towns and cities across Europe, and although this technology may be new to most passengers, we have been supplying storage solutions for alternative fuel vehicles for over 30 years.

At Luxfer we provide a full design and build for the complete fuel storage solution, including our lightweight G-Stor H2 Type 3 aluminium lined cylinder wrapped in aerospace-grade carbon fibre, piping, regulation systems and ready-to-fit frames.

All systems are certified to the latest regulations, giving peace of mind to passengers, bus companies and operators alike.

By designing a bespoke system to fit each bus, Luxfer works with manufacturers to provide the optimum balance between capacity and weight. Our system ensures that a bus can complete a full shift without needing to refuel, whilst keeping weight to a minimum.

We believe that hydrogen fuel cells are the best green alternative to petrol and diesel for bus systems, giving the equivalent power, performance and range while dramatically cutting emissions. These systems will help restore clean air in cities and significantly reduce the carbon footprint of the transport industry. We’re excited and inspired to be part of this ever advancing movement.

The Future of Fuel

Hydrogen presents an eco-friendly, regenerative and sustainable energy source and is an ideal replacement for fossil fuels in the transportation sector. Here at Luxfer, we have over 30 years of experience working with the gas. We are continually innovating our cylinder and system technologies and specialise in working with forward-thinking companies to harness the full potential of hydrogen power for bespoke transport projects.

As the world’s largest ISO approved manufacturer of lightweight, high-pressure composite and aluminium cylinders and member of the Fuel Cell & Hydrogen Energy Association (FCHEA) and the UK Hydrogen and Fuel Cell Association (UKHFCA), we have unrivalled industry-leading expertise in designing and supplying hydrogen storage systems.

Environmental concerns have focused research and development efforts on hydrogen as an alternative fuel to power the needs of our daily lives. For example, in electric vehicles, it is used to run fuel cells which convert the gas efficiently into electrical energy.

The UK has pledged a green industrial revolution, creating jobs and infrastructure to achieve net-zero emissions by 2050. With our track record in the hydrogen market, and continued investment in our alternative fuel capability, Luxfer Gas Cylinders are committed to playing a central role.

“With the government’s new environmental vision, hydrogen provides a very attractive alternative to diesel transport and electricity,” commented Dr. Mark Lawday, Luxfer’s head of European sales. “Our recent projects are an excellent example of Luxfer’s commitment to a clean, green economy across the globe.”

As demand increases across a wide range of applications in Europe, the focus on hydrogen as a fuel is clearly shifting away from a niche market into one that is much more accessible and expansive. It’s even influencing an international step-change in the approach to decarbonisation efforts.

At Luxfer, we believe in creating a greener world for future generations, and we’re passionate that hydrogen is the key to safe and sustainable transport. We’re working with a number of commercial vehicle manufacturers around the world to supply industry-leading hydrogen cylinders and, in many cases, to design hydrogen fuel systems to meet the highest technological and safety requirements.

What are the benefits of Luxfer hydrogen systems?

1. Lightness of weight from G-Stor H2 carbon composite cylinder technology increases fuel economy and reduces wear and tear.
2. Luxfer is ISO 9001 approved and our systems are manufactured in an ECE R110 approved facility.
3. Cost-saving - 1 gallon of petrol has about the same amount of energy as 1kg of hydrogen.
4. Quiet operation and fewer moving parts decreases noise pollution and gives a smoother ride.
5. Zero harmful emissions - when used in a fuel cell, hydrogen produces zero emissions, the only by-product is water vapour.
6. Range - similar to conventional petrol vehicles, quick and easy to refill: 1-minute for 1kg of hydrogen = 100 km range.
7. Better performance - high torque and high efficiency from electric drive-train.
8. Energy conservation – system idles when not in use to preserve energy, a regenerating brake system recycles energy back into the batteries, while an energy storage system provides extra boost for accelerating and tackling inclines.
9. Lowers sound pollution – quieter vehicles cut noise in urban areas.

How do hydrogen systems work?

Hydrogen-powered vehicles use fuel cells to convert the chemical energy in the gas (stored under pressure in cylinders) to electrical energy via an electrochemical process - fuel cells do not combust hydrogen, but instead combine it with oxygen in a chemical reaction that produces electricity for power. The only tailpipe emission is water.

This process is extremely efficient – nine litres of water can produce one kilogram of hydrogen. And that kilogram of hydrogen contains about 33 kilowatts of energy which, in the case of a small road vehicle, can power the electric motor and achieve a range of around 100 kilometres.

The efficiency of water electrolysis is between about 70-80%, with a goal set to reach 82-86% efficiency by 2030 using proton exchange membrane (PEM) electrolyzers.

If the energy required to produce the hydrogen gas, in the initial instance, comes from a sustainable or renewable source then the potential is practically unlimited. Of course, in reality hydrogen production is still quite reliant on less green methods, but investment in wind, wave, biomass and solar power, combined with our own internal policies on reducing our alternative fuel system manufacturing footprint and recyclable cylinders, will make great strides towards this. Well-to-wheel emissions of a hydrogen fuel-cell car are nonetheless currently about 30% lower than those of a conventional diesel-powered car.

How does a hydrogen fuel cell work?

Fuel cell systems are a clean, efficient, reliable, quiet and scalable power source. There are no moving parts and they do not need to be recharged like batteries and continue to produce electricity as long as fuel is present.

The cell is made up of an anode, cathode, and an electrolyte membrane. Passing hydrogen through the anode splits the hydrogen molecules into electrons and protons. The protons pass through the membrane, while the electrons go into a circuit, generating the electric current. At the cathode, the hydrogen protons and oxygen combine to produce water.

Further efficiencies are achieved in the vehicle design using techniques such as regenerative braking, idle-stop and onboard batteries to store excess energy.

How is the hydrogen stored?

In cylinders, and as part of custom-built systems. Our G-Stor H2 products are the leading line of lightweight, impermeable, high-pressure carbon composite hydrogen-storage cylinders. They are used by some of the world’s largest OEMs that design, develop and manufacture state-of-the-art compressed hydrogen-storage systems for fuel-cell and internal combustion engines.

The G-Stor H2 is also available with our proprietary high-pressure hydrogen electronic solenoid valve, resulting in a certified, cost-effective hydrogen-storage solution that is ideal for transport applications.

G-Stor H2 cylinders are also being used for mobile refuelling systems that provide “instant infrastructure” by making compressed hydrogen immediately accessible to end-users.

European Business Development Manager, Jim Gregory said, “We have been making high-pressure gas storage for 80 years, and we have been at the forefront of every technological advancement in that time. Over the next two years, our industry is going to see a step-change in the variety of new applications for hydrogen in areas we perhaps did not even think of a few years ago.”

Learn more about G-Stor H2 hydrogen cylinders

Hydrogen fuel applications

Hydrogen Buses

Hydrogen Trains

Hydrogen Trucks

Hydrogen Boats

At Luxfer, we believe in creating a greener world for future generations, and we’re passionate that hydrogen is the key to safe and sustainable transport. We’re working with a number of commercial vehicle manufacturers around the world to supply industry leading hydrogen cylinders and, in many cases, to design hydrogen fuel systems to meet the highest technological and safety requirements. We are proud to have already been involved in several 'world's first' projects, including hydrogen trains, buses and boats.

This animation highlights some of many possible, and exciting, applications of hydrogen fuels. Come on an environmentally friendly journey with us, each step we take is a step closer to a greener future.

This video was an introduction to the Mission: Hydrogen GmbH Online Workshop, which took place on 25th March 2021. The interactive event explored industry-led questions with over 100 world-class experts, more than 150 exhibitors, and 15,000 participants.

In this video from Luxfer CEO Alok Maskara, you can find out more about Luxfer’s contribution to this vital field, and the steps we are taking to ensure hydrogen fuel solutions are available to all nations and all industries in order to meet global zero-carbon goals.

The term “hydrogen economy” refers to a future in which hydrogen, rather than fossil fuels, is used as the primary fuel for transportation, heating, industry, and many other applications. Replacing fossil fuels with hydrogen systems will help combat global warming and allow nations across the world to make significant progress towards their green goals.

Hydrogen is much more sustainable and environmentally friendly than fossil fuels, because the only waste product that comes from using hydrogen fuel is harmless water vapour.

For years, Luxfer has been leading the way in the design and innovation of hydrogen fuel systems so that they can be easily integrated with other technologies to provide green solutions across countless industries.

Our state-of-the-art hydrogen fuel cylinders can be used in numerous applications, from public transport to industrial haulage, from agriculture to delivery services. We have become pioneers in the field, with our technology setting the standard for future change.

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