Chapter 1 INTRODUCTION Environmental awareness is increasing as India has embarked on a massive boost to industrial and infrastructure development. The number of industries in India have increased manifold in the last few decades changing the situation to an impressive progressive prospect. Increased industrial production has resulted in the growth of this country but concurrently it has also resulted in production of hazardous waste (HW). Central Pollution Control Board (CPCB) has compiled state-wise inventory of hazardous waste generating industries in a document “National Inventory of Hazardous Waste Generating Industries and Hazardous Waste Management in India” in February 2009 based on the data received for the year 2007-08 from State Pollution Control Boards (SPCB) and Pollution Control Committees (PCC) [CPCB, 2009]. As stated in the document, there are 36,165 different HW generating industries generating 6.2 million metric tons of HW every year in India. Of these, 2.7 million metric tons (43.78%) qualify to be disposed off into a secured landfill while 0.4 million metric tons (6.67%) qualify for incineration and remaining 3.1 million metric tons (49.55%) are categorized as recyclable. The states of Gujarat, Maharashtra, and Andhra Pradesh are the top three landfillable waste generating states [CPCB, 2010]. 1.1. Indian regulatory framework Hazardous waste generated by the industries can cause environmental pollution and adverse health effects if not handled and managed properly. The Ministry of Environment and Forests, Government of India, notified Hazardous Waste (Management and Handling) Rules on July 28, 1989, under the provisions of the Environment (Protection) Act of 1986 for effective management of HW, mainly solids, semi-solids and other industrial wastes, which do not come under the purview of the Water (Prevention and Control of Pollution) Act 1974 and the Air (Prevention and Control of Pollution) Act 1981. These rules were further amended in the years 2000, 2003 and in September 2008 were repealed and the new rules entitled “Hazardous Waste (Management and Handling and Trans boundary Movement) Rules 2008” (referred as HW (M, H & TM) Rules) were notified. These rules were further amended in the year 2009. The rules define various categories of hazardous waste based on the process listing (waste streams) and concentration of hazard components. The Notification includes 26 rules, VII Schedules and 15 forms [CPCB, 2010]. 2 The objectives of these rules were to restore and maintain the chemical, physical and biological integrity of the air, water and land environment for the nation. The rules made it compulsory for industry to use specialized equipment and services for the storage, handling, treatment, transportation and disposal of hazardous waste in an environmentally sound manner. State Pollution Control Boards, pressure from non-governmental organizations (NGOs) and environment activists are helping to bring about stringent enforcement of pollution control rules. HW has been defined as in rules 2009 as any waste which by reason of any of its physical, chemical, reactive, toxic, flammable, explosive or corrosive characteristics causes danger or is likely to cause danger to health or an environment, whether alone or when in contact with other wastes or substances and shall include : (i) Industrial process based hazardous wastes (Schedule 1): The industrial processes based classification seeks to identify for various industries and processes from which hazardous wastes are generated. This classification also identifies the wastes in a tabular form making it easy for regulators to classify wastes into hazardous and non-hazardous and includes wastes generated mainly from the 36 industrial processes (Annexure 1). (ii) Concentration based standards for hazardous wastes (Schedule 2): In the concentration based classification, the rules identify metals and organics whose presence beyond a certain concentration renders it to be classified as hazardous. The wastes are classified into five classes and their subsequent subclasses (Annexure 2). (iii) General characteristics based hazardous wastes: This set of classification is based on the general characteristics of the waste, called CRIT criteria as follows: Corrosive (pH <2 or > 12.5): It corrodes metals or has a very high or low pH. This is known as a "corrosive" waste. Examples are rust removers, acid or alkaline cleaning fluids and battery acid. Reactive (unstable, releases toxic fumes with water and other conditions): It is unstable and explodes or produces toxic fumes, gases, and vapors when mixed with water or under other conditions such as heat or pressure. This is known as a "reactive" waste. Examples are certain cyanides or sulfide-bearing wastes. Ignitable: (Flash Point < 60oC; oxidizers): It catches fire under certain conditions. This is known as an "ignitable" waste. Examples are paints and certain degreasers and solvents. 3 Toxic (classified on basis of Toxicity Characteristics Leachate Procedure, test method as followed by USEPA, vide no: SW 846, till Indian standards are notified by MoEF/CPCB): It is harmful or fatal when ingested or absorbed or it leaches toxic chemicals into the soil or ground water when disposed of on land. This is known as a "toxic" waste. Examples are wastes that contain high concentrations of heavy metals. Refer table 1.1 for the contaminants concentration limits given in Management of Hazardous Wastes, Guidelines for Proper Functioning and Upkeep of Disposal Sites, HAZWAMS/32/2005-2006, and fig.1.1. for decision chart for waste categorization [CPCB, 2006]. Table 1.1. TCLP test limits for heavy metals as per HAZWAMS/32/2005-2006 Sr. No. Contaminant TCLP Limit (mg/L) 1 Arsenic 5.0 2 Barium 100.0 3 Cadmium 1.0 4 Chromium 5.0 5 Lead 5.0 6 Mercury 0.2 7 Selenium 1.0 8 Silver 5.0 Organic contaminants from the standards are not mentioned *Note: 1. 2. 3. These limits shall be applicable till the notification of Leachate Standards (including Test Method) under the E (P) Act, 1986 Best Demonstrated Available Technology (BDAT) standards shall be employed for parameters not mentioned. 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Decision chart to assign waste category. 1.2. United States Environmental Protection Agency (USEPA) regulatory framework In United States major regulatory considerations for clean up and disposal of hazardous waste are primarily regulated by two federal laws and their amendments. First is the Resource Conservation and Recovery Act (RCRA) of 1976 as amended by the Hazardous and Solid Waste Amendments of 1984 (HSWA). These give USEPA, authority to regulate disposal of hazardous waste and set standards for treatment. The second major law regulating hazardous waste is the Comprehensive Environmental Response Compensation and Liability Act (CERCLA) of 1980 as amended by the Superfund Amendments and Reauthorization Act (SARA) of 1986. CERCLA regulates the cleanup of spilled materials and abandoned hazardous waste sites [USEPA, 1993]. Toxic Substances Control Act (TSCA) regulates toxic chemicals and mixtures that present an unreasonable risk of injury to human health or an environment. USEPA is required to establish treatment standards for each type of RCRA hazardous waste. These are established on the basis of the Best Demonstrated Available Technology (BDAT), rather than on risk based or health based standards. “Best” is defined as the technology 5 that offers the greatest reduction of toxicity, mobility or volume of the waste. To be “demonstrated” treatment technology must be demonstrated to work at a full scale level, as opposed to bench scale or pilot scale. “Available” means that a technology is commercially available [USEPA, 1993]. USEPA has listed specific hazardous wastes based on the criteria set forth in 40 CFR 261.11 under RCRA. If a waste meets the listing definition, it is presumed to be hazardous, regardless of its concentration. The wastes are listed according to their toxicity, reactivity, corrosivity and ignitability and includes a) nonspecific sources (F codes), b) specific sources (K codes), c) commercial chemical products which are acutely hazardous (P codes) and d) commercial chemical products which are non-acutely hazardous ( U codes) [Wagner, 1991]. European Waste Catalogue has core list of 850 types of wastes, of these 420 are classified as hazardous wastes and are divided into 19 main categories. 1.3. Treatment scenario Waste minimization, reuse, recycle (reduce, reuse, recycle) at source, leads to considerable onus upon the industries to develop methods, it is also important that safer disposal methodologies should be developed at the end of the pipe line strategy. The HW should be properly treated prior to its disposal. Treatment defined in HW (M, H & TM) rules is a method, technique or process designed to change the physical, chemical or biological characteristics or composition of any HW so as to render such wastes harmless which essentially would mean to reduce the leachable properties apart from other criteria. A few disposal methods (apart from reduce, reuse, recycle) are landfill and incineration. Landfilling has been by far the most popular method employed in contaminated land remediation due to its simplicity, reliability and relatively low cost [Harbottle et al., 2007]. Inert wastes, which do not leach toxic metals or organics, can be landfilled at Hazardous Waste Treatment, Storage and Disposal Facilities (TSDF) as per the prescribed guidelines. Presently there are 26 common TSDFs in operation in 12 states, across the country and 35 new sites notified are at different stages of development. All the wastes, however, can not be put directly into the landfill. A landfill operator comes across many metals bearing wastes which have leaching properties when extracted with water or acid. These leached metals could impact the ground water or soil in the immediate vicinity of a landfill. Even Government of India has formulated 6 guidelines for landfillable waste. One of the criteria which do not allow the wastes into the landfill is based upon the concentration of pollutants in the leachate. CPCB has given guidelines for proper functioning and upkeep of disposal sites and concentration limits for acceptance of hazardous wastes for direct disposal to secured landfill under Hazardous Waste Management Series, HAZWAMS/32/2005-2006 (table 1.2). These guidelines mandate a few wastes to be treated in order to reduce the leachable properties of the wastes to render them landfillable. There would be a need to stabilize (treat) these wastes using a plethora of methods like solidification, alkali chlorination, neutralization, hydrolysis, precipitation, encapsulation, etc. These treatment methods of wastes in hazardous waste parlance are called stabilization methods, wherein wastes are subjected to many processes and subsequently put into landfills. Stabilization process is effective in treating a variety of difficult to manage wastes to render them suitable for landfilling or for reuse or recycle. Table 1.2. Concentration limits/criteria for acceptance of hazardous wastes for direct disposal to secured landfill as per HAZWAMS/32/2005-2006 Leachate quality * pH Concentration 4-12 Total phenols < 100 mg/L Arsenic < 1 mg/L Lead < 2 mg/L Cadmium < 0.2 mg/L Chromium (VI) < 0.5 mg/L Copper < 10 mg/L Nickel < 3 mg/L Mercury < 0.1 mg/L Zinc < 10 mg/L Fluoride < 50 mg/L Ammonia < 1000 mg/L Cyanide < 2 mg/L Nitrate < 30 mg/L Calorific value < 2500 Kcal/Kg Strength Unconfined Compression Test > 50 KN/m2 *Leachate quality is based on water leach test. 7 1.4. Stabilization/solidification As mentioned in subsection 1.3, solid waste management gives high priority to the development of technologies addressed towards recycling and reuse. In the former case, wastes are recycled to the same process from which they are generated, while in the latter case, they are reused in a different process. High priority is also given to the recovery of raw materials and energy from waste, however, these requirements can not always be satisfied because a proper technology may be too expensive or may not be available. In such circumstances, the priority is given to treatment processes which will reduce the environmental impact of the wastes. Amongst these processes, stabilization/solidification (S/S), are most suitable and are already widely used for the treatment of hazardous industrial solid wastes. Cement based S/S often lead to formation of monolithic products which may have potential to be used in the field of pre-formed building materials [Cioffi et al., 2002]. The origin and development of S/S technology was first time described by Jesse Conner, [1990]. S/S is a proven technology for the treatment of hazardous wastes. It involves the addition of binders which can effectively achieve a) chemical treatment (stabilization) of the hazardous wastes by converting the contaminants into less toxic, mobile and insoluble and b) mechanical conversion (solidification) of the waste into a durable, dense and monolithic entity with structural integrity that is more suitable for storage, landfilling or reuse [Conner, 1990; Conner and Hoeffner, 1998; Marwa et al., 2007]. S/S refers to the conversion of waste to a more chemically stable form. This conversion may include solidification, but it often includes the use of physicochemical reactions to transform the contaminants to less mobile or toxic forms [Means et al., 1995]. It is an important tool in the treatment of sludge, soils and combustion residues contaminated with hazardous materials. The process is increasingly being used in the remediation of contaminated sites and has lot of advantages such as speed of implementation, facilitation of rapid development of the site, reduction of offsite disposal, reduced risk to site workers and use of well established techniques and equipment [Harbottle et al., 2007]. The process inhibits leaching of hazardous components by reducing waste/leachant contact and by forming a stable pH environment in which many heavy metals of environmental concern remain insoluble [Fitch and Cheeseman, 2003]. It involves mixing of hazardous wastes in the form of sludge or solid, into cementitious 8 binder system and is most suitable for treating predominantly inorganic wastes, especially those wastes having heavy metals are considered to be more compatible with the types of cementitious binders normally used [Roy et al., 1992a; Fatta et al., 2004]. Currently cementitious solidification/stabilization is recognized as the “BDAT” by USEPA for the land disposal of most toxic elements (table 1.3) and for 57 RCRA listed hazardous wastes. S/S technology was selected in 24% of all source control treatments at Superfund remedial action sites in United States [USEPA, 2004]. Hence, they are most widely used of all hazardous waste management alternatives [Kundu and Gupta, 2008]. The cementitious binder can be ordinary Portland cement (OPC) or admixtures of OPC with fly ash. The technology aims to change the release process from a percolation dominated mechanism to diffusion or surface–dissolution dominated regime. The wastes are incorporated into the cement matrix and undergo physical and chemical change that further reduces contaminant mobility. The mobility and possible release of metal contaminants are decreased through their precipitation as hydroxides, adsorption or ion substitution in cement hydration products and physical encapsulation in the solid matrix [Islam et al., 2004]. Most hazardous wastes can be incorporated into a waste cement system. The suspended pollutants would be incorporated into the final hardened concrete. During this solidification process the concrete formation binds and strengthens the mass, coats and incorporates some contaminants molecule in the siliceous solids and blocks pathways between the pores. Thus this process is highly effective for waste components with high levels of toxic metals. The alkaline matrices such as lime and cement are commonly used in waste conditioning because they are inexpensive, readily incorporates wet wastes and their alkalinity reduces the solubility of many inorganic toxic or hazardous metals [Kundu and Gupta, 2008]. Typically hydroxides of metals are formed which are less soluble as compared to other ionic species. Small amounts of fly ash or bentonite can be added to alter porosity. It has been applied to the plating wastes containing metals [USEPA, 1989a]. The technology appears both cost effective and safe and its relative simplicity has made this an attractive pre-landfill waste treatment technology that aims at making selected hazardous industrial wastes safe for disposal at hazardous waste sites [ASTM 1989; USEPA, 1989a; Chang et al., 1999; Asavapisit et al., 2003; Fitch and Cheeseman, 2003]. 9 Table 1.3. BDAT for RCRA Wastes Waste description BDAT treatment Barium S/S (one alternative) Cadmium S/S ( one alternative) Chromium S/S (one alternative) Lead S/S Mercury S/S Selenium S/S Silver S/S Wastewater treatment sludges Alkaline chlorination + pptn + S/S Spent CN plating bath solutions Alkaline chlorination + pptn + S/S Plating sludges from CN processes Alkaline chlorination+pptn + S/S Spent stripping and cleaning solutions Alkaline chlorination + pptn + S/S From CN processes Spent CN solutions from salt bath cleaning Electrolytic oxidation +Alkaline chlorination + pptn + S/S BDAT: Best Demonstrated Available Technology RCRA: Resource Conservation & Recovery Act 1.5. Literature review Cement based S/S has been used extensively for treating inorganic solid wastes containing heavy metals such as As, Cd, Cu, Ni, Pb and Zn [Bhatty et al., 1999]. Many experimental and modelling studies are found in literature relating to the subject. S/S processes are usually categorized based on the type of additives through which solidification is achieved [Sharma and Lewis, 1994]. Each technique has certain advantages and disadvantages. Cement and pozzolan based techniques are preferred mainly due to low cost and good solidification characteristics [Parira and Yuet, 2006]. The formation of insoluble hydroxides is an important aspect of cement based S/S technology. The solubility of Cd, Cr, Cu, Pb, Ni and Zn hydroxides decreases with increasing pH upto pH 10 [Cullinane et al., 1986; Shi and Spence, 2004]. Above this pH, the solubility increases with pH as the metal cations form soluble complex anions with excess hydroxide ions. The variation of metal hydroxide solubility with pH is an 10 important factor for the S/S process because pore solution of hydrated cement paste is highly alkaline [Mollah et al., 1995]. Arsenic containing waste can be solidified/stabilized with cement, fly ash and Ca(OH)2. The formation of calcite seals the pores of the solidified sample and precipitate formation of calcium arsenite whereas cement acts as a binder [Singh and Pant 2006; Kundu and Gupta 2008]. The effects of Cr on different Portland cement phases and the solidification of Cr in cementitious matrices have been studied by various researchers [Stephan et al., 1999; Omotoso et al., 1996; Vallejo et al., 1999; Park, 2000; Trezza and Ferraiuelo, 2003; Fatta et al., 2004; Halim et al., 2004; Polettini et al., 2004]. Copper can also be effectively immobilized using cement based and lime based S/S treatment [Yukselen and Alpaslan, 2001; Fatta et al., 2004]. Zain et al. [2004] have shown that the waste copper slag from blasting operation can be safely stabilized in cement based system. There are many studies on the S/S treatment of Ni with Portland cement [Roy et al., 1992b, 1993, Fatta et al., 2004.] and cement fly ash [Roy et al., 1993]. Roy et al. [1992b] observed that the hydration of Portland cement was retarded by Ni containing sludge. They suggested that physical encapsulation of metal hydroxide by the cement is principle mechanism of stabilization. Lead concentration in leachate after S/S by Portland cement has been found to be dependant on the leachate pH [Halim et al., 2003]. In a study using cement binders, Coz et al. [2004] showed that the concentration of Zn in leachate under a wide range of pH was very similar to that calculated based on the solubility of hydroxide ions. Silveira et al. [2003] studied effectiveness of cement based systems for S/S of spent potliner (SPL) inorganic fraction. They have concluded that cyanide and fluoride mobilities were substantially reduced and S/S effectiveness for the leachable cyanides and fluorides were 59.33 and 57.95% respectively. Sarla et al. [2004] have treated cyanide successfully in aqueous solution with oxidation by chemical and photochemical process. Malviya and Chaudhary [2006] reviewed factors affecting hazardous waste S/S. The significant conclusions were design of S/S equipment and infrastructure depending on the expected waste content or loading of the final waste form. Important parameters to assess S/S are strength, setting time and extent of hydration. Metal bearing waste can have either positive or negative effect on the strength development. Different waste metals have different effects individually and in combination with binders in a S/S matrix. 11 Factors affecting strength development in order of importance are cement content, curing time and water:solid ratio. Species like sulphate affect strength development. Sodium sulphate affects S/S of a synthetic electroplating sludge in cementious binders with microstructure and microchemistry study [Roy et al., 1992a]. Hydration can be retarded depending upon the quantity and type of waste species. Setting time also changes with waste addition. Carbonation affects waste by improving mechanical and chemical properties. Gerven et al. [2007] have studied the effects of carbonation and leaching on porosity in cement bound waste. The vulnerability of the stabilized waste to physical and chemical attacks depends on factors such as permeability, chemical composition and microstructure of the cement and incorporated waste aggregates [Klich et al., 1999]. Ageing and weathering affect chemical, physical and microstructure properties of waste material. The effect of freezing and thawing and wetting and drying on solidified mercury containing sludge was studied and degradation of solidified monoliths was observed [Gordon, 1993]. Kearsley and Wainwright [2002] have established relationships between porosity and strength. Despite interferences and some negative effects on cement matrices, S/S waste with cement based techniques, clearly passes current quality acceptance criteria for disposal in most cases. Leaching models are important tools in evaluating the efficiency of immobilization by S/S treatment technologies. The models can help to identify leaching mechanisms and can provide methods for correlating leach data, estimate leaching of contaminants over longer periods of time and may be helpful in developing improved binder and additive formulations for S/S. SOLTEQ-B is a mathematical model developed for predicting the behavior of S/S waste for risk assessment [Batchelor, 1998; Park and Batchelor, 2002]. It was perceived from the literature review that there is scarce published research work on the mixed waste with reactive and toxic contaminants. This was specially noticed during data collection on treatments of Ba containing wastes. While there is some accessible data on alkali chlorination of cyanide wastes, especially liquid wastes; very less data is available on stabilization of solid wastes containing cyanide. Similarly, even though available data on S/S of radioactive wastes containing barium exists; not much information could be gathered on S/S of solid wastes containing Ba. There is a definite need for investigating approaches for treatment of such wastes. The present work was, therefore, undertaken with the specific objective of researching these wastes and developing an effective technique for their remediation. 12 1.6. Waste material and contaminants The machinery industry generate, cyanide from processes like plating, metal finishing, heat treating and wet mining and pollute the environment. Metalworking and finishing operations are large users of sodium, potassium, and calcium cyanides in heat treating and nitriding operations. The quenching process in these operations produces cyanide contaminated oils and wastes that need to be eventually disposed off. Quench waters from hardening operations such as nitriding contains ferrocyanide as well as cyanide [Conner, 1990]. The presence of untreated CN waste in landfill is potentially hazardous because of the possibility of its impact on air, soil and groundwater. This leaching shall have an adverse impact on human beings, if not handled appropriately. Experimental studies of CN wastes (generated from heat treatment process) disposed in landfills showed that between 72 and 82% of the CN was converted mostly to ammonium and organic nitrogen compounds, whereas between 4 and 22% of the CN leached as free or complex CN and up to 11% remained in landfill [Lagas et al., 1982]. Generally it is present in waste streams as simple and complex cyanide, cyanates and nitriles. The stability of cyanide complexes is pH dependent and hence their potential environmental impacts can vary. Although, metal cyanide complexes by themselves are less toxic than free cyanide, their dissociation releases free cyanide as well as the metal cation which can also be toxic and may lead regulatory issues and environmental concerns [Sarla et al., 2004; Dash et al., 2008]. The first category of RCRA listed hazardous wastes with F code includes generally material specific wastes generated by a variety of processes. This category of wastes includes solvent wastes, electroplating wastes, metal heat treating wastes and dioxin coating wastes [Wagner, 1991]. The waste material considered for research studies belonged to this category and the main contaminants were barium and cyanide. All cyanide species are considered to be acute hazardous materials and have therefore been designated as P-Class hazardous waste according to RCRA [Young and Jordon, 1995]. Barium is one of the eight priority pollutants listed under RCRA metals as toxicity characteristic metal for which USEPA has established required treatment level using Toxicity Characteristic Leaching Procedure (TCLP) [Conner, 1997]. The other metals listed are As, Cd, Cr, Pb, Hg, Se and Ag. Certain barium compounds such as nitrate, chloride are relatively water soluble whereas the fluoride, carbonate, sulfate salts have very low solubility. The water solubility of barium salts increases with decreasing pH except for barium sulfate. There is no evidence that barium is carcinogenic however 13 several cases of poisoning due to ingestion of barium compounds like chloride or carbonate have been found to be toxic in adult humans [World Health Organization, 1990]. The metals in the waste can be treated by precipitation; but cyanide must be removed prior to precipitation of metals since, it acts as a complexing agent which inhibits precipitation [Chung, 1989]. It has been reported that, 59.33% effectiveness was achieved in the cement based stabilization system for cyanide containing spent potliners waste without any pretreatment for its removal [Silveira et al., 2003]. Cyanide is normally destroyed by oxidation, specially, by alkali chlorination, which leads to its decomposition to carbon dioxide and nitrogen [Clements and Griffins, 1985; Chung, 1989]. The fixation or destruction of cyanide is of importance in stabilization/solidification. Barium can be easily stabilized by precipitation, well below RCRA levels. Even with extremely high barium wastes, sodium sulphate or gypsum can be added to any standard stabilization formulation to precipitate barium as barium sulphate. Barium sulphate is not toxic due to its low solubility 1.4 mg/L as barium in water [Conner, 1990, 1997]. 1.7. Aims and objectives of this study To devise a suitable treatment technique for the barium cyanide waste, generated by engineering tools manufacturing industry, for its safe disposal into secured landfill at a Common Hazardous Waste Treatment Storage Disposal Facility (CHWTSDF). 1. Comprehensive characterization of the BaCN waste to establish its compliance with regulatory norms. 2. To identify and evaluate suitable additives, binders and waste:binder ratios during the screening trials for final treatability experiments. 3. To identify and evaluate suitable performance tests and techniques for efficacy of stabilization. 4. Optimization of stabilization process for final treatability experiments. 5. Verification and in situ validation of the process. 6. Cost evaluation. Barium cyanide is one of the 57 listed RCRA wastes for which stabilization is identified as one of the “BDAT” by EPA under code P013 (for commercial chemical products) with Reference 55 FR 22561 [Means et al., 1995]. Hazardous waste can be 14 stabilized in a variety of ways, but the main objective was to develop a recipe that produces a stable and sustainable end product, which will pose minimal threat to the environment [Sloot et al., 2007]. The stabilization trials on the said waste were undertaken initially in the laboratory. The TSDF is provided with well equipped laboratory where laboratory as well as onsite (in situ) trials were conveniently possible. The results obtained for S/S bench scale experiments in laboratory were validated for safe disposal of waste in secured landfill as per USEPA and CPCB guidelines. The research aspects of the study are discussed in detail in subsequent chapters. The technology screening and materials and methods used in the treatability experiments are discussed in next Chapter (2). 15
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