Wednesday, April 17, 2019

Luckey Magnesium Plant Played Important Part in World War II


At the intersection of State Route 582, Gilbert and Luckey Roads just north of Luckey, Ohio sits a broken and forlorn reminder of a bygone age: the wartime factory that once housed the Magnesium Reduction Company. Built on a crash basis in the early days of World War II due to a national shortage of magnesium, the plant has not been used in more than 15 years, and the Army Corps of Engineers is actively engaged in cleaning up the plant site with plans to tear down the factory within the next few years. It is a sad ending for a structure that once formed an important part in the Arsenal of Democracy which gained the victory in World War II.


Magnesium Reduction Co. plant at Luckey, Ohio (Luckey Historical Society)
          At the outset of World War II, the United States found itself desperately short of magnesium and the Axis powers controlled 60% of the world’s total output. Pre-war production of this metal occurred only at the Dow Chemical Company’s plant in Midland, Michigan which could produce about 18 million pounds per year. Forecasted demand for magnesium, bolstered by President Roosevelt’s directive to ramp up U.S. aircraft output to 50,000 planes per year, far outstripped Dow’s capacity. “The War Production Board recommended that magnesium production be extended more than 90 times that of 1939, to approximately 610 million lbs,” a government report stated in 1942. Production totals in 1941, buttressed by the opening of two more plants, supplied only roughly 5% of that forecasted demand. “Events in 1941 forecast that an unprecedented quantity of magnesium would be required for military purposes for the production of aircraft and incendiary bombs. Demand for the metal was much greater than the supply and to meet military requirements, mandatory priorities were invoked on magnesium on March 3, 1941.” This action placed all sale and distribution of magnesium firmly under Federal government control.

The dilapidated plant shown in a photo from April 2019. The exposed south wing of the plant once housed 20 furnaces in which magnesium was "reduced" from ferrosilicon and calcined dolomite.
The Federal government, through the War Production Board, embarked on a rapid industry expansion to cover the magnesium shortfall. The expansion occurred in two phases; the first phase in 1941 called for the construction of eight new plants, but by February 1942 projected magnesium needs rose to 725 million pounds and drove a second wave of expansion totaling seven more plants: the Luckey plant was part of this second expansion. The new facility, with a designed capacity of 10 million pounds per year, required 120 million pounds of dolomite per year and this fact played a major role in determining where the plant was built. A national search conducted to identify plant sites sufficiently close to both raw materials and railroads identified northwest Ohio, noted for its abundant limestone industry and extensive railroad network, as a natural choice. “In this district there are large deposits of dolomite and of suitable quality.  Natural gas and electric power are available. In the vicinity of the site there are several lime plants from which calcined dolomite can be obtained and it was decided to purchase the calcine instead of installing facilities to produce it,” wrote National Lead Co. engineer Andrew Mayer in 1944. The National Gypsum Co. quarry located on Gilbert Road directly across the street from the plant supplied the calcined dolomite which was then delivered in 12-ton batches via dump truck while the ferrosilicon was brought in on railcars. The New York Central Railroad, specifically its Toledo & Ohio Central branch line, handled all rail traffic to and from the plant. With the New York Central’s Stanley Yard located only a few miles north, expedited delivery of the vital metal to war industries was considerably enhanced.

General plan layout of the plant as built in 1942. The Production Control Bldg. (no. 12 on the map) on the southwest corner of the facility was built first and served as a training facility for new employees. It was later used to develop improved techniques and practices for the plant. (Andrew Mayer, National Lead)
With the Luckey site identified, the Defense Plant Corporation (a Federal entity) entered into an agreement with National Lead Company in May 1942 in which the DPC would build and own the $5 million magnesium plant, while National Lead (which formed a new subsidiary called the Magnesium Reduction Company) would operate the facility. The DPC purchased the land from Melissa A. Laymen on June 1, 1942 and construction quickly commenced. United Engineering & Development Co. of Philadelphia undertook the construction job under the guidance of architects Singmaster and Breyer of New York and completed their work by December. The plant featured two parallel wings: the northern wing housed the briquetting operation while the reduction furnaces were set along the southern wing. Shortages of construction materials and workers slowed construction progress. “All primary facilities under construction experienced delays in obtaining structural steel, electrical equipment, and the complicated components necessary for the completion of the plants,” reported the chairman of the U.S. War Production Board in 1945. Andrew Mayer reported that “steel was conserved as much as practicable in construction on account of emergency conditions.” A shortage of workers, a common problem for U.S. industry in World War II, played a role in the delayed startup. “The work is progressing so rapidly that already applications for the hundreds of workers that will be required are being taken at a room in the Hotel Secor,” the Toledo Blade reported.

The finishing press, shown above, for the completed briquettes was located in the northern wing of the main plant building. The briquetting process took a while to fine tune but by early 1944, the plant was operating at more than 20% above its rated capacity of 10 million pounds per year.
One of the first buildings completed was the production control unit that featured a furnace with four full-scale retorts and auxiliary equipment. This site, later used as a laboratory for improving plant processes, opened in October as a training facility for plant personnel prior to full scale production beginning on December 30, 1942. Eventually the plant operated 400 retorts in 20 furnaces which enabled the facility to produce in excess of 14 tons per day of finished magnesium ingots.

          Pre-war magnesium was produced by processing brine to extract pure magnesium through electrolysis; this was known as the Dow process. But with urgent wartime needs to be met, several new methods of magnesium production were explored and the Luckey plant employed what is known as the ferrosilicon reduction process, named the Pidgeon process in honor of chemist Dr. Lloyd Montgomery Pidgeon of the Canadian Research Council who developed the process in 1941. This process today is the predominant method by which magnesium is produced.


Map showing the locations of the 16 U.S. plants that produced magnesium for the war effort. It is worth noting that Dow Chemical Co. operated four of these plants (Midland and Marysville, Michigan, and Freeport and Velasco, Texas); Dow operated the only plant in the country producing magnesium when the war began and was the only producer left standing after the war ended. It is worth noting that the location of the plants tended to cluster near areas where there was large-scale aircraft manufacturing; the California and Nevada plants supplied magnesium for the aircraft industry centered in southern California. The Ford-operated Dearborn plant supplied magnesium for aluminum used at the Ford-operated Willow Run plant which built thousands of B-24s. (Author's Map)
The primary components for producing magnesium through the Pidgeon process are dolomite and ferrosilicon. The input materials are crushed and ground in separate processes; the dolomite is processed through a calciner which yields calcium oxide and magnesium oxide. The ferrosilicon is produced in an arc furnace which generates 75% grade ferrosilicon, scrap iron, and coke. (Both of these materials were shipped into the Luckey plant from other producers.) Ferrosilicon is then mixed with the CaO and MgO and condensed to form the briquettes. The briquettes were fed into “tubular retorts of chrome-nickel steel set horizontally in a furnace with the open ends projecting outside the front wall,” wrote Andrew Mayer in 1944. “The retorts are then closed and evacuated.” Reduction took place under vacuum at about 2,130 degrees Fahrenheit and the vaporized magnesium separated from the rest of the mixture and condensed in the water-cooled removable sleeve section of the retort. This magnesium deposit, called a muff, was removed from the 10” diameter retort at the end of the cycle and sent along the process to be re-melted and cast into ingots.  “For the daily rated capacity of 14 tons of magnesium there are required approximately 170 tons of dolomite and 16.5 tons of ferrosilicon,” Mayer wrote. Retort residue which was trucked off site as waste amounted to 87 tons per day.

A photo showing a portion of the furnace house in 1943; each furnace housed 20 retorts (the circular doors are the retorts) and the plant operated 20 furnaces. The gas-fired furnaces utilized burners supplied by Surface Combustion Co. which even today operates in the Toledo area.
“Attention was drawn to the Pidgeon process because it requires a minimum of electrical power (chiefly that used in the production of ferrosilicon), it utilizes dolomite (which is very abundant), and a plant can be erected in a relatively short time. The process, however, necessitates substantial expansion of ferrosilicon production capacity and the use of a large quantity of critical nichrome steel for manufacture of retorts.” (Minerals Yearbook, 1941, pgs. 747-748) The Pidgeon process offered a number of other advantages important in wartime: “It does not require a highly trained workforce or sophisticated engineering and only requires a small amount of capital cost.”

Betty Wormley, a 1943 graduate of Pemberville
High School, worked at the Luckey plant
during the war.
Demand for magnesium was one of the most challenging aspects of the national defense program when the Luckey plant commenced operations in December 1942. “During the emergency period, firms sent most of the metal to aircraft plants leaving little available for other purposes. Despite the fact that industry expanded its facilities as rapidly as possible, for a time there was simply not enough metal for the armed forces,” wrote Leo Brophy.

“Through the entire year of 1942, the use of magnesium had to be curtailed, urgent export demands were not fully met, and powder was not available in the requested amounts for flares and ammunition,” Julius A. Krug of the War Production Board wrote in 1945. “However, it was the incendiary bomb program which bore the brunt of the shortage, receiving only 11.4 million pounds of magnesium compared with the greatly reduced calculated requirements of 62 million pounds. Although a substitute thermite bomb had been developed, it could not replace entirely the urgent need for incendiaries in the European theater.”

Operations started off slowly as the normal production problems were sorted out and improved methods devised. The briquetting operation proved most troublesome at first as it took a while to figure out how to make a sufficiently strong briquette. It was found that binder could not be used in the process, and the finishing presses suffered from excessive maintenance costs and power consumption. Over time, a two-stage briquetting process was developed which used a coarser calcine and this yielded better results.  Each retort load took five bags (235 lbs) of briquettes and took about 10 hours to complete the reduction cycle; the removable sleeve was then extracted from the furnace by a machine and the 31-lb magnesium muff was driven out of the sleeve with a pneumatic hammer. The remaining waste product was emptied out via discharge screws into hoppers and the retort prepared for its next charge. The magnesium muff moved on to the alloy building at the eastern end of the plant where it was “melted down and mixed with other metals by usual methods to make alloys for incendiary bombs and aircraft parts,” Mayer wrote. The retorts after repeated use would start to collapse and after about 250 days would fail altogether. Replacement of the retorts, which used expensive and hard-to-acquire chrome-nickel steel (also called nichrome steel), was a downside of using the Pidgeon process and this additional cost ultimately contributed to the plant closing at the end of the war.

An extraction machine was used to empty the scorching hot retort at the end of the reduction cycle. The retorts, made of expensive and difficult-to-obtain nichrome steel, lasted about 250 days before they collapsed and had to be replaced. The reduction cycle lasted about 10 hours and produced 31 pounds of magnesium per cycle; at best operations got two cycles a day out of each retort.
Luckey-produced magnesium ended up in two primary destinations for war use: incendiary bombs and aircraft components. Early war allocations gave most of the magnesium to the aircraft industry, but by the end of 1943 the allocation between the armaments and aircraft industries became even. In the aircraft industry, 64% of the magnesium was used in the manufacture of engines and propellers, 23% used in wheels, 7% for aircraft frames, and 6% for accessories. Types of aluminum-magnesium alloys included Birmabright (1-7% Mg, remainder Al), Magnalium (5% Mg, 95% Al), and Duralumin (1.2-1.8% Mg). “Wartime experience and advances have shown that the metal is easily machined and that its alloys with aluminum, zinc, and copper are not only very light, but high in strength.” (Minerals Yearbook, 1943, pg. 774) As the war progressed, the metal also started to be used for rocket-launcher tubes, flares, and tracers.

Luckey also supplied material which was used for explosives. Magnesium was used both in bomb casings and as powder for incendiary bombs.  In early 1941 “the Joint Aircraft Committee, established to allocate American material between the United States and Great Britain, recommended that the Ordnance Department to produce a four-lb. magnesium bomb suitable for the Army, Navy, and the British. Ordnance thereupon modified the British Mark II/A four-lb. incendiary and standardized it as the American AN-M50. Most of the bombs went to Great Britain on Lend-Lease and were dropped in air raids over Europe. Aircraft dropped more four-lb. magnesium bombs than all other incendiary bombs put together. Almost 30 million fell on Europe, and almost 10 million on Japan, causing damage that ran into astronomical figures,” wrote Brophy

Workers at the Luckey plant are shown utilizing a pneumatic hammer to punch out the magnesium "muff" from the removable sleeve of the retort. The muff was sent to the alloy building where it was remelted and cast into alloy ingots for use in the aircraft industry or for use in incendiary bomb production. Empty sleeves are lined up on the right of the photo; the muff was the shape with a hole in it on the left.
The Luckey plant’s stated capacity was 10 million pounds of processed magnesium per year, and the plant reached its peak figure in 1944 when 12,384,000 pounds was produced. The Luckey plant garnered two Army-Navy E Awards (E for excellence) for its production efforts during the war. The first award was presented on February 16, 1944 in impressive ceremony at the plant that was attended by military and governmental representatives, including former women’s tennis champion Helen Hull Jacobs who was then serving in the U.S. Navy. Fletcher W. Rockwell, president of National Lead Co., accepted the plant award from Colonel E.W. Dennis of the 5th Service Command. It is unclear when the second award was given.

The Troy High School Band performed at the Luckey plant during the first Army-Navy E Award ceremony which took place February 16, 1944. Production facilities earned an E Award for excellence in meeting WPD production goals; the Luckey plant earned two of these awards by the time in ceased operations in August 1945. National Lead's president Fletcher Rockwell attended the ceremonies as did tennis star Helen Hull Jacobs. Note the collection of flags in the background, each of which represented one of the Allied countries engaged against the Axis. It was an intensely patriotic time and the plant workers took great pride in their contributions to the war effort. If victory in WWII was borne upon the wings of the air forces, those wings were made possible by the efforts of plants like the Luckey magnesium plant that produced the essential raw materials of victory. (Luckey Public Library) 
By the beginning of 1944, the Federal government possessed a burgeoning surplus of magnesium and began to either curtail operations or close plants altogether. Production had increased to more than 367 million pounds in 1943 and far exceeded demand. In February 1944, the first round of production curtailments went into effect followed by a series of curtailments and plant closures throughout the year. In October 1944 the War Production Board removed all restrictions on the use of magnesium but this generated little if any additional demand upon the national stockpile. “A survey of the wartime record leaves no doubt that the industry was greatly over expanded, even for war, but the great difficulty in predicting war demands made this inevitable. The fact remains, however, that both private industry and the government possess magnesium-producing facilities far in excess of any demand foreseeable for at least a decade after the war,” reported the 1944 Minerals Yearbook. It is worth noting that the highest demand for magnesium came in 1943 and totaled 362 million pounds, roughly half the 725 million-pound figure projected by the War Production Board in February 1942.

U.S. production of magnesium rose rapidly as a result of the national expansion to 16 plants; it as a classic case of overproduction as plants that went online in 1943 were shuttered the following year. Even though the Luckey plant was one of the smallest in the nation, the high quality of the magnesium produced kept the plant doors open until the war ended in August 1945. (Author's graphic)
By January 1, 1945, the War Production Board had shut down 79% of national magnesium capacity and yet the country still possessed a healthy stockpile of magnesium.  The Luckey plant, however, avoided all of these closures and continued operating right up to the close of hostilities in August 1945. Production ceased altogether that month with annual production totaling 7,296,000 pounds. Despite the plant’s efficiency, its production costs (30 cents per pound) “could not hope to compete in a market in which magnesium sells for 20.5 cents and in which capacity exceeds demand.” (Minerals Yearbook, 1945, pg. 768) “Orders to close the plant were issued two weeks ago by the Reconstruction Finance Co. according to E.R. Rowley, plant manager,” the Toledo Blade reported on September 4, 1945. “The product extracted from the dolomite rock of Wood County was rated as the purest magnesium produced in the U.S. But its production costs were double the costs of pre-war magnesium.”


Satellite image of the plant from the early 2010s. The traces of the railroad tracks to the east of the plant are clearly visible. The Army Corps of Engineers is busily engaged in efforts to clean up the contaminated soils around the plant and plan to eventually tear down most if not all of the plant buildings. (Google Earth)
The plant was placed in stand-by mode and remained idle until 1949 when the Brush Beryllium Company moved in to produce beryllium for the Atomic Energy Commission. While operating under AEC direction, radioactive steel was brought unto the plant site and that, combined with the beryllium, left the plant a contaminated facility. It was designated as a Superfund site in 1992 under FUSRAP (Formerly Utilized Sites Remedial Action Program) and recent estimates show that it will take 12 years and $244 million to fully resuscitate the property. Tons of contaminated soil will need to be removed to cleanse the area of beryllium, lead, radium, thorium, and uranium.
Signs warning visitors of both the beryllium and radioactive hazards adorn the fence surrounding the plant. Visitors would do well to abide the warnings and limit their sight-seeing to outside the fence. Honestly, unless you like looking at crumbling gutted buildings, there isn't much worth seeing anymore. (Author's photo)

Sources:

“Big U.S. Magnesium Plant to be Located at Luckey,” Toledo Blade, June 10, 1942

“Notables at Luckey for E Award Rites,” Toledo Blade, February 16, 1944

“Wood County Loses Magnesium Plant,” Toledo Blade, September 4, 1945

Mayer, Andrew. “Plant for the Production of Magnesium by the Ferrosilicon Process” American Institute of Mining and Metallurgical Engineers, Technical Publication No. 1670, 1944

Wulandari, Winny, et al. “Magnesium: current and alternative production routes.” University of Wollongong, Australia, 2010


Government Documents:

Background Review of the Brush Beryllium and Diamond Magnesium Plants in Luckey, Ohio. Department of Energy: Formerly Utilized Sites Remedial Action Program. 1989


Brophy, Leo P., Wyndham D. Miles and Rexmond C. Cochrane. The Chemical Warfare Service: From Laboratory to Field. Washington: Center of Military History, 1988


Bureau of Mines, United States Department of Interior Minerals Yearbooks:

Shore, F.M. Minerals Yearbook 1941. Washington: Government Printing Office, 1943

Needham, C.E., editor. Minerals Yearbook 1942. Washington: Government Printing Office, 1943

Needham, C.E., editor. Minerals Yearbook 1943. Washington: Government Printing Office, 1945

Needham, C.E., editor. Minerals Yearbook 1944. Washington: Government Printing Office, 1946

Keiser, H.D editor. Minerals Yearbook 1945. Washington: Government Printing Office, 1947

Krug, Julius A. Wartime Production Achievements and the Reconversion Outlook. Report of the Chairman of the Chairman, War Production Board. Washington: Government Printing Office, 1945



U.S. Magnesium Industry in World War II

Yearly production totals:
1941           32,589,052 lbs.
1942           97,925,684 lbs.
1943           367,168,000 lbs. (183,584 short tons)
1944           314,200,000 lbs. (157,100 short tons)
1945           65,584,000 lbs. (32,792 short tons)
Yearly domestic consumption totals:
1941           29,346,600 lbs.
1942           84,525,700 lbs.
1943           281,654,000 lbs. (155,547 short tons)
1944           265,396,000 lbs. (132,698 short tons)
1945           86,000,000 lbs. (43,000 short tons)
Yearly export totals:
1941           3,098,424 lbs. (2.3 million lbs. to England)
1942           8,090,449 lbs. (7.1 million lbs. to England)
1943           80,858,000 lbs. (63.8 million lbs. to England, 7.2 million lbs. to USSR)
1944           48,396,000 lbs. (32 million lbs. to England, 10 million lbs. to USSR)
1945           1,036,000 lbs. (560 thousand lbs. to USSR, 420 thousand lbs. to Mexico)
Prewar Production:
Dow Chemical Co.
Midland, Michigan                                                         Capacity: 18 million pounds/year
Continued production postwar
June 1941 Expansion:
Basic Magnesium
Las Vegas, Nevada                                                         Capacity: 112 million pounds/year
Opened: August 31, 1942
Curtailment: 40% effective April 1, 1944
Curtailment: additional 20% effective July 25, 1944
Production Ended: August 31, 1944
Diamond Magnesium
Painesville, Ohio                                                   Capacity: 36 million pounds/year
Opened: late September 1942
Curtailment: 25% effective September 25, 1944
Curtailment: additional 25% effective November 25, 1944
Production ended: by September 1945
Dow Chemical Co.
Freeport, Texas                                                     Capacity: 36 million pounds/year
Opened: Late 1941
Production ended: by September 1945
Dow Magnesium
Velasco, Texas                                                               Capacity: 72 million pounds/year
Opened: June 1942
Curtailment: 50% effective August 31, 1944
Production ended: by September 1945
International Minerals and Chemicals (Union Potash)
Austin, Texas                                                                 Capacity: 24 million pounds/year
Opened: November 1942
Production Ended: August 31, 1944
Mathieson Alkali Works, Inc.
Lake Charles, Louisiana                                        Capacity: 54 million pounds/year
Opened: June 6, 1943
Production Ended: April 1, 1944
Permanente Metals Corp.
Richmond, California                                                     Capacity: 24 million pounds/year
Opened: Late 1941
Production ended: by September 1945
Union Potash
Carlsbad, New Mexico                                                    Capacity: 24 million pounds/ year
Opened: June 1943
Production ended: by September 1945
February 1942 Expansion:
Amco Magnesium Co. (American Magnesium Co.)
Wingdale, New York                                                      Capacity: 10 million pounds/year
Opened: March 1943
Curtailment: 33% effective February 1, 1944
Production Ended: June 1, 1944
Dow Magnesium
Marysville, Michigan                                                      Capacity: 72 million pounds/year
Opened: April 8, 1943
Curtailment: 40% effective May 1, 1944
Production Ended: July 25, 1944
Electro-Metallurgical Co.
Spokane, Washington                                                     Capacity: 48 million pounds/year
Opened: May 26, 1943
Curtailment: 50% effective March 1, 1944
Curtailment: additional 16% effective July 25, 1944
Production ended: by September 1945
Ford Motor Co.
Dearborn, Michigan                                                        Capacity: 40 million pounds/year
Opened: May 1942
Production Ended: March 1, 1944
Magnesium Reduction Co.
Luckey, Ohio                                                                  Capacity: 10 million pounds/year
Opened: December 30, 1942
Curtailment: 40% effective November 25, 1944
Production ended: by September 1945
New England Lime Co.
Canaan, Connecticut                                                       Capacity: 10 million pounds/year
Opened: September 1942
Curtailment: 60% effective October 15, 1944
Production ended: by September 1945
Permanente Metals Corp.
Manteca, California                                                        Capacity: 20 million pounds/year
Opened: August 1942
Curtailment: 50% effective March 1, 1944
Production Ended: June 1, 1944
Process Types:
Electrolytic separation (Dow Process)
Dow Chemical Co.
Freeport, Texas                                                     Capacity: 36 million pounds/year
Midland, Michigan                                                         Capacity: 18 million pounds/year
Dow Magnesium
Marysville, Michigan                                                      Capacity: 72 million pounds/year
Velasco, Texas                                                               Capacity: 72 million pounds/year
International Minerals and Chemicals (Union Potash)
Carlsbad, New Mexico                                                    Capacity: 24 million pounds per year
Carbo-electrothermic reduction (Hansgirg Process)
Permanente Metals Corp.
Permanente, California                                                   Capacity: 24 million pounds/year
Ferrosilicon reduction (Pidgeon Process)
Amco Magnesium Co.
Wingdale, New York                                                      Capacity: 10 million pounds/year
Diamond Magnesium
Painesville, Ohio                                                   Capacity: 36 million pounds/year
Electro-Metallurgical Co.
Spokane, Washington                                                     Capacity: 48 million pounds/year
Ford Motor Co.
Dearborn, Michigan                                                        Capacity: 40 million pounds/year
Magnesium Reduction Co.
Luckey, Ohio                                                                  Capacity: 10 million pounds/year
New England Lime Co.
Canaan, Connecticut                                                       Capacity: 10 million pounds/year
Permanente Metals Corp.
Manteca, California                                                        Capacity: 20 million pounds/year

Magnesite (M.E.L Process)
Basic Magnesium
Las Vegas, Nevada                                                         Capacity: 112 million pounds/year

                                              Trail-Mathieson Cell Process
Mathieson Alkali Works Inc.
Lake Charles, Louisiana                                        Capacity: 54 million pounds/year
Magnesium Plant Expansion
Plant Opening Date
Dow- Midland, MI Jan-41
Dow-Freeport, TX Oct-41
Permanente-Permanente, CA Oct-41
Ford- Dearborn, MI May-42
Dow- Velasco, TX Jun-42
Permanente- Manteca, CA Aug-42
Basic- Las Vegas, NV 31-Aug-42
Diamond- Painesville, OH Sep-42
New England- Canaan, CT Sep-42
IMM- Austin, TX Nov-42
Magnesium- Luckey, OH 30-Dec-42
Amco- Wingdale, NY Mar-43
Dow- Marysville, MI 8-Apr-43
Electro-Spokane, WA 26-May-43
Union- Carlsbad, NM Jun-43
Mathieson- Lake Charles, LA 6-Jun-43


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