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FLUE GAS DRYING OF BAGASSE

C. M. Kinoshita

ABSTRACT and construction stage in the continental U.S. at the time.


Technical data on commercial systems using boiler flue Hence, experience with that practice was lacking. Those in
gas to dry bagasse, the fibrous byproduct of milled Hawaii considering installing bagasse dryers were
sugarcane that fuels sugar factory boilers, will be presented concerned not only with a wide array of potential problems
in this article. The results of this study are based primarily but with increased dust and stack emissions; rather limited
on four systems installed in Hawaii during the late 1970s improvement in boiler efficiency achievable with bagasse
and early 1980s. Even though the temperatures of the flue drying, given the relatively low flue gas temperatures
gases available for bagasse drying in Hawaiian sugar which prevailed in the Hawaiian sugar industry; possibly
factories are generally much lower than in factories large parasitic energy requirements of the equipment
elsewhere, the improvements in boiler efficiencies in (motors for drive conveyors, fans, etc.) supporting the
Hawaii due to flue gas bagasse drying were found to be drying system; and accelerated corrosion in the dryer
roughly 5 percentage points which is substantial. The heat system, especially when fuel oil is fired concurrently in the
loss from the dryer system and the related ducting was boiler. In spite of these concerns, the first bagasse dryer
generally found to be minimal, < 0.5% of the heating value system in Hawaii was installed in 1978; three other
of the bagasse fuel. Carbon monoxide concentration (and installations followed shortly thereafter.
the associated loss) was significantly lower and boiler Three of the four installations - at the Hamakua Sugar
stack emissions and opacity usually improved substantially Company (on the island of Hawaii), HCPC (island of
when the bagasse was dried prior to being burned in the Hawaii), and Waialua Sugar Company (island of Oahu) -
boiler. have rotary bagasse dryers (Table 1) with materials-
This article discusses bagasse drying compared with handling cyclones to remove the bagasse fines that are
other methods of heat recovery; factors that can be used to entrained in the dryer drum from the moisture laden gas
gauge the effectiveness of heat recovery; and identifies exiting the dryers. One installation - at the Paia factory of
practices that can reduce the effectiveness of bagasse HC&S Company (on the island of Maui) - has a "flash"
drying. KEYWORDS. Dryers, Bagasse, Heat recovery. (cyclonic) dryer. Design and operational information for
each cogeneration/dryer system can be found elsewhere
(Kinoshita, 1989). This article describes the technical
INTRODUCTION aspects of flue gas bagasse drying systems in the Hawaiian

F or decades, hot flue gas was viewed as a readily sugar industry and discusses the experiences of factories
available source of thermal energy to dry bagasse, that practice bagasse drying.
the fibrous byproduct of milled sugarcane, to make it
more suitable for various possible commercial uses.
However, it was not until 1975 that the worldwide sugar
BAGASSE DRYING VERSUS OTHER
community, spurred by the need to conserve energy, METHODS OF HEAT RECOVERY
installed its first commercial dryer system using flue gas Bagasse boiler efficiency varies widely throughout the
from bagasse boilers to dry bagasse prior to combustion Hawaiian sugar industry, from 55% to nearly 70%
(Furines, 1976). Since then, the number of reported
commercial bagasse dryer systems installed throughout the
TABLE 1. Type of dryer, dryer operating pressure, percentage of
world has grown to at least ten (Arrascaeta and Friedman, gas and bagasse bypassing the dryer, and change in excess air across
1987) (several installations not reported in the literature the dryer/cyclone system at four Hawaiian sugar factories
have also been seen by this author); of these, four were
Dryer Type/ Gas Bagasse Change in
installed in Hawaii. Operating Bypass Bypass Excess Air
In the mid 1970s, when the Hawaiian sugar industry Factory Pressure (%) (%) (%age Points)
first seriously contemplated using flue gas to dry bagasse, Hamakua rotary/
there were no commercial systems operating in the world, Sugar Co. vacuum 25 40 50
although two bagasse drying systems were in the planning
HCPC rotary/
vacuum 40 0 30
Article was submitted for publication in April 1991; reviewed and HC&S Co.- flash/
approved for publication by the Food and Process Engineering Inst, of Paua Factory atmospheric 40 65 0
ASAE in August 1991.
The author is Charles M. Kinoshita, Hawaii Natural Energy Inst., Waialua rotary/
University of Hawaii at Manoa, Honolulu. Sugar Co. vacuum 10 15 30

VOL. 7(6): NOVEMBER 1991 © 1991 American Society of Agricultural Engineers 0883-8542 / 91 / 0706-0729 729
(Kinoshita, 1990), as does the type of heat recovery systems without dryers but with other heat recovery
equipment used - air preheaters, economizers, and flue gas devices.*
bagasse dryers. Considering heat recovery as part of the EPA Method-5 tests (USEPA, 1977) conducted on the
steam generation system, for a given set of conditions - four bagasse drying systems in the industry indicate an
fuel moisture content, flue gas temperature, and excess air average gas temperature at the exit of the dryer cyclone of
entering the heat recovery device - the effectiveness of 90° C (200° F), with three of the four systems averaging
heat recovery can be gauged completely by 1) the flue gas 75° C (170° F); however, all systems allow a portion of the
temperature exiting the heat recovery device, 2) the excess hot flue gas to pass around the dryer. This brings the
air in the flue gas exiting the device, 3) the combustion effective flue gas temperature - the weighted mean of the
losses (unburned fuel as char and incomplete products of cold gas exiting the dryer cyclone and the hot gas
combustion, such as carbon monoxide) which result from bypassing the dryer - to 100-150° C (210-300° F),
the use of the device, and 4) the heat loss from the device. averaging 115° C (240° F) for the four Hawaiian systems
These factors are discussed individually below. (the average effective flue gas temperature for the three
rotary dryer systems is 105° C (220° F). By comparison,
FLUE GAS TEMPERATURE the three boiler systems equipped with both economizers
Flue gas temperatures (after the last heat recovery and air heaters, but without dryers, have an average stack
device) vary widely throughout the Hawaiian sugar temperature of about 155° C (310° F).
industry - from below 100° C to over 300° C (200° F to The moisture content of the dried bagasse depends
600° F) (fig. 1). Based on simple energy balances, it can primarily on the moisture content of the undried bagasse,
be shown (Kinoshita, 1988) that boiler efficiency increases the excess air in the flue gas, and the flue gas temperature
linearly as stack temperature decreases, by roughly one drop across the dryer. The calculated moisture content of
percentage point for each 15° C (27° F) drop in dried bagasse, as a function of flue gas temperature drop
temperature under typical industry conditions (bagasse across the dryer for various undried bagasse moisture
moisture content -45-50% and excess air ~50-100%). content and excess air, assuming that all of the bagasse
When bagasse is dried with flue gas, both heat and mass burned is dried by all of the flue gas in an adiabatic dryer
transfer takes place, as opposed to heat transfer alone with system with no entrained tramp air, is shown in figure 2.
air heaters and economizers. The temperature of the cold (Here, the relative rates of bagasse and flue gas, which
stream (i.e., the moist bagasse) remains nearly constant and affect drying, are implicitly in the excess air.) Although
relatively low throughout the heat recovery device (at or data for only a single dryer inlet temperature, 260° C
below the wet bulb temperature, unlike economizers and (500° F), are presented in figure 2, the data are valid (to
air heaters, for which the temperature of the cold stream within about three percentage points) for dryer inlet
continuously increases). Hence, thermal energy in the flue temperatures between 150° and 400° C (300° and 750° F),
gas can be recovered more readily with waste heat bagasse since the temperature drop across the dryer system
dryers than with other conventional heat recovery devices. influences the amount of drying that occurs more than the
This is illustrated quite dramatically in figure 1, which
shows that flue gas temperatures in boiler systems with
bagasse dryers are much lower, on average, than in boiler * For boiler systems with bagasse dryers, the flue gas temperature
data presented in figure 1 are weighted averages of the gas temperature at
the dryer exit and the temperature of the gas bypassing the dryer.

^s °1 Undried bagasse moisture content (%)


Exit (

6 0 - 460)
•yer

50- >^L
IExcess A r (%)
40- ^ 0 ) ^
""""^ 0
Bagasse Mo sture

30-
\ „ 50
20-
Wai Hai HCP Pio Lih Pai Oah Kek Puu Kau McB Olo
Factory 10- Xs °
\100
100 50 100 0 50
Notes . 0- r I
Characters above bars signify installation of following heat recovery devices
D: Bagasse dryer 0 100 200 300
E: Economizer
A: Air heater Temperature Drop Across Dryer (°C)
N: No heat recovery device installed
Similar shading denotes comparable heat recovery devices
Figure 2-Bagasse moisture content at dryer exit vs. temperature drop
Figure 1-Flue gas heat recovery devices installed and gas across dryer for various dryer inlet moisture content (numbers in
temperature after heat recovery in Hawaiian bagasse boiler systems. parentheses), and excess air; gas temperature at dryer inlet is
(Note: For systems with bagasse dryers, flue gas temperature is assumed to be 260° C (500° F). Arrows denote dew point temperature
weighted average of temperature of gas at dryer cyclone exit and gas (beyond which the curves are extrapolated in the vapor phase) for the
bypassing dryer.) particular conditions assumed.

730 APPLIED ENGINEERING IN AGRICULTURE


dryer inlet temperature or dryer outlet temperature alone. enters upstream of or within the dryer/cyclone system
(For fixed flue gas temperature drop across the dryer, the reduces the potential for heat transfer thus increasing the
moisture content of the dried bagasse would be slightly size of dryer required for equivalent drying; and the tramp
higher at high dryer inlet temperatures than at low dryer air increases the fan power required to convey the flue gas,
inlet temperatures, i.e., less moisture would be evaporated the wear rate of system components, and the amount of
at high temperatures as more of the heat transferred from bagasse fines that pass through the cyclone system.
the flue gas would be expended in the sensible-heating of
the water vapor to the higher dryer outlet temperature.) The LOSSES DUE TO INCOMPLETE COMBUSTION
computational results presented in figure 2 are extrapolated Losses due to incomplete combustion should decrease
in the vapor phase (disregarding condensation) to dryer exit as bagasse moisture content decreases, but the degree to
temperatures below the dew point (which are designated by which this occurs has not been studied extensively. The
arrows), so that the data may be applied to dryer inlet only commercial-scale test known to the author comparing
temperatures above 260° C (500° F) as long as the exit carbon monoxide (CO) losses with and without a dryer,
temperature remains above the wet bulb. In cases in which was the Waialua Sugar Company bagasse dryer test
part of the flue gas or bagasse bypasses the dryer system, conducted in 1981 (Kinoshita, 1989). In that test, with an
the data presented in figure 2 may still be used by adjusting average reduction in bagasse moisture content due to
the flue gas temperature or bagasse moisture content to its drying of five percentage points, Orsat measured CO
effective value (i.e., the weighted mean of the streams concentration decreased by an average of 0.14 percentage
passing through and bypassing the dryer). The point when the bagasse dryer was operating. Under the
computations may also be adjusted to account for heat loss conditions of the test, based on comparative CO versus
from the dryer system by reducing the temperature drop CO2 heats of combustion, this translates to a 0.7 percentage
across the dryer to its effective value since the amount of point increase in boiler efficiency with the use of the
heat transferred between the flue gas and the bagasse is bagasse dryer.
proportional to the change in flue gas temperature across Other related changes accompanying bagasse drying,
the dryer. In general, the measured bagasse moisture such as reduced unburned-carbon (char) loss and increased
contents have agreed with predicted values to within physical loss of fuel, especially bagasse fines, due to
~3 percentage points. Details and assumptions of the increased handling of the bagasse, have not been
analysis and a discussion of the effect of tramp air entering quantified, however, they are believed to be quite small.
the dryer system are given elsewhere (Kinoshita, 1988).
Table 1 suggests that in every system in the industry at HEAT LOSS
least 10% of the total flue gas available is not being used to In three of the four systems examined in this study, the
dry the bagasse (i.e., it bypasses the dryer system). The heat loss, as determined from infrared pyrometer
fraction of flue gas bypassing the dryer appears to be measurements on the outer surfaces of the major dryer
increasing at some factories. This is due, in part, to a loss system components or computed on the basis of mass and
in dryer system fan capacity over time aggravated by energy balances from changes in flue gas temperature and
greater infiltration of tramp air into the dryer system which composition across the dryer system while no bagasse was
increases the power required by the fan. In addition to being dried, was found to be <0.5% of the higher heating
using only part of the gas to dry the bagasse, only a portion value (HHV) of the bagasse fuel. Such losses are minor -
of the milled bagasse is dried at most factories (Table 1). on the order of one-tenth of the typical gains in boiler
This may have economic justification. Some feel that for a efficiency attributable to bagasse drying. The relatively low
given amount of flue gas it is less costly to dry only a level of heat loss was due to the ducting and dryer casing
portion of the bagasse to a lower moisture content and then being well-insulated and the flue gas temperatures in the
mix the dried and undried bagasse to produce a blend with vicinity of the dryer being fairly low. In only one of the
intermediate moisture content, than to dry all of the four systems studied (the flash dryer system) was the heat
bagasse (Miller, 1981). This may be true under certain loss determined to be substantial (-1.0% of the HHV of the
circumstances as some drying costs tend to scale with the bagasse burned and 2-3% of the HHV of the bagasse
amount of bagasse dried. In general though, maximizing actually dried). In this particular case, the unit was not well
the flue gas and bagasse rates through the dryer results in insulated and the ratio, exposed surface arearbagasse
maximum heat recovery. throughput rate, was much higher than the others.

EXCESS AIR PARASITIC ENERGY REQUIREMENT


In general, bagasse with lower moisture content requires Bagasse drying requires much auxiliary equipment
less excess air for complete combustion; however, most of (conveyors, fans, etc.) to handle the loose bagasse and flue
the boiler systems with dryers investigated showed fairly gas in and around the dryer system. This results in a much
high levels of excess air exiting the stack. This appeared to larger parasitic energy demand than the more conventional
be primarily due to the entrainment of substantial amounts methods of heat recovery. Based on designs and equipment
of tramp air in and around the bagasse dryers which usually installed, the average parasitic power requirement for the
operate under vacuum. Orsat measurements made in this four dryer systems installed in Hawaii is estimated to be
study have indicated that the amount of tramp air leaking about 12 kWh per tonne (15 hph per ton) of bagasse dried,
into just the dryer/cyclone portion of steam generation the largest component being the incremental fan power
systems equipped with rotary dryers is equivalent to at load. Calculations made during this study indicate that for
least 30% excess air (Table 1). Such high levels of tramp the average Hawaiian cogeneration system with a bagasse
air can have several negative consequences: air which dryer, an increase in boiler efficiency of ~2 percentage

VOL. 7(6): NOVEMBER 1991 731


TABLE 2. Change in particulate emissions opacity attributable to flue gas bagasse drying
for various bagasse bi /dryer systems in Hawaii
Change (%) in
Factory
(Test Date) Emissions Opacity* Comments
Hamakua Sugar -26 NA Main dryer stack versus dryer-bypass stack
Co. (1981)

Hamakua Sugar -30 -18 Main dryer stack versus dryer-bypass stack
Co.(1981)

Waialua Sugar -42 -26 Dryer-on versus dryer-off


Co. (1981) 50% bagasse dried with 50% of flue gas

HCPC(1981) +22 NA Dryer stack versus dryer-bypass stack


Data collected prior to dryer-cyclone
modification

HCPC(1983) -75 NA Dryer stack versus dryer-bypass stack


Data collected after dryer-cyclone modification

HCPCQ985) -24 NA Dryer stack versus dryer-bypass stack


* NA indicates not measured.

points would be required just to recover such a parasitic from the entrapment of gas particulates in the dryer drum
load. In terms of recovery of flue gas energy, this is and in the cyclone with the dryer in operation.
equivalent to a reduction in gas temperature of ~30° C Bagasse boiler emissions tests have been performed on
(~50° F). Given that factories with bagasse dryers have nearly every Hawaiian bagasse boiler, but usually for
effective stack temperatures of about 100° C (-200° F) or regulatory purposes only. Therefore, except for the
higher, it does not seem practical from a net energy aforementioned Waialua Sugar Company test, the effect of
standpoint to adopt bagasse drying unless the temperature flue gas bagasse drying on boiler emissions was not studied
of the flue gas to be used for drying is, say, 200° C explicitly. Nevertheless, in most emission tests involving
(400° F) or higher. boiler systems with bagasse dryers, particulate emissions
Some studies on bagasse drying (e.g., Keenliside, 1983) and gas composition and flow rate were measured from the
have suggested that drying of bagasse with flue gas dryer stack and from the dryer-bypass stack. (In these
provides very little net exportable energy, i.e., the systems, separate stacks were installed to emit the gas
incremental electrical power that results with bagasse which passed through the dryer and which bypassed the
drying barely covers just the parasitic power requirement dryer.) Those data permit calculation of the particulate
of the dryer system. By contrast, information compiled in emissions rate per unit of carbon in the gas stream from the
this study suggests that bagasse dryer systems in Hawaii dryer stack and from the dryer-bypass stack. In tests on
are, in general, sound from a net energy standpoint. For boiler systems with bagasse dryers performed by the HSPA
example, the three rotary dryer systems have a power during 1981-1985, the rate of particulate emissions per unit
generation:power consumption ratio of 2.7 to 3.7, of carbon in the gas stream from the dryer stack varied
averaging 3.1; only the flash dryer system has a ratio below widely from 75% below to 22% above the rate from the
1.5. dryer-bypass stack (Table 2). Nevertheless, the particulate
emissions rate was generally much lower for the gas stream
which passed through the bagasse dryer than the stream
CONTROL OF STACK EMISSIONS which bypassed the dryer, reinforcing the conclusion of the
Numerous EPA Method-5 type tests performed by the Waialua Sugar Company test that drying bagasse with flue
Experiment Station of the Hawaiian Sugar Planters' gas can reduce boiler stack emissions.
Association (HSPA) on sugar factory stack emissions have From the standpoint of emissions control, the most
indicated that drying bagasse with flue gas can have a important component in the dryer system is the dryer
significant positive or negative effect on boiler particulate cyclone. Changes in the dryer cyclone have led to dramatic
emissions and stack opacity. Probably the most differences in the amount and composition of emissions
comprehensive test performed in Hawaii was the 1981 from the dryer/cyclone system (figs. 3 and 4, and Table 2).
HSPA test on the boiler/dryer system at Waialua Sugar For example, at one factory, prior to modifying the cyclone
Company (Kinoshita, 1989). Although only one-half of the system, the combustible fraction of the particulates exiting
gas was used to dry just one-half of the bagasse in that test, the dryer stack more closely approximated that of the
the effect of drying bagasse with flue gas on both unburned bagasse than the particulates which passed
particulate emissions and opacity was dramatic and through the furnace (in the dryer-bypass stream). After
favorable. Specific emissions rate (mass of particulate modifying the cyclones, the combustible fraction more
emissions per unit mass of fiber burned) decreased by 42% closely approximated that which passed through the
and boiler opacity decreased by 26% when the dryer furnace than the unbumed bagasse. In most instances, the
system was in use. It is believed that the substantial particulates exiting the dryer system have a significantly
reduction in emissions resulted from better combustion, higher fraction of combustibles than the particulates in the

732 APPLIED ENGINEERING IN AGRICULTURE


....... r f V* • Dryer-bypass stack
H Dryer stack
100

..£- 80-
o
' ** M »•• E 60 -•
LL

W 40 -•
XI
E
o 20
o

-•if
Before Modification After Modification
Figure 4-CombustibIe fraction in flue gas particulate matter sampled
from the dryer stack and from the dryer-bypass stack prior to and
following modification to the cyclone system at a Hawaiian sugar
factory (corresponds to samples shown in fig. 3).

gas stream which bypass the dryer system. This indicates


that much of the particulates are unburned bagasse fines
ik \ which are entrained into the gas flow in the bagasse dryer
and which pass through the cyclone unit, further
." > underscoring the importance of the cyclone system in
controlling particulate emissions.
Stack opacity almost always improves with bagasse
» .»...'*•
drying. This is partly the result of the usual reduction in
particulate emissions with bagasse drying. Also, the gas
•:V that passes through the dryer/cyclone system often
y>
* ... approaches its dew point and the vapor in the plume
condenses above the dryer stack making the plume appear
to be water scrubbed (fig. 5).
•,,v

SUMMARY AND CONCLUSIONS


Although the temperatures of the flue gases available
for bagasse drying are, in general, much lower in Hawaiian
sugar factories than in factories elsewhere, the
improvements in boiler efficiencies in Hawaii due to flue
gas bagasse drying were still found to be roughly 5
percentage points which is substantial. The heat loss from
the dryer system and the related ducting was generally
found to be minimal, <0.5% of the heating value of the
bagasse fuel. Carbon monoxide concentration (and the
associated loss) was significantly lower and boiler stack
emissions and opacity usually improved substantially when
7^r ^ «-vr &% the bagasse was dried prior to being burned in the boiler.
While drying bagasse with flue gas prior to firing has
significant energy, environmental, and economic benefits,
there are some operational and maintenance problems
relating to the practice that are worth noting. Although
drier bagasse should require less excess air for thorough
combustion, most of the boiler systems in Hawaii with
Figure 3-Flue gas particulate matter sampled in the gas stream from bagasse dryers displayed relatively high and increasing
the dryer stack (left) and the dryer-bypass stack (right) prior to
modification to the cyclone system (above) vs. after modification to levels of excess air at the exit of the dryer system, due
the cyclone system (below) at a Hawaiian sugar factory. primarily to the entrainment of substantial amounts of

VOL. 7(6): NOVEMBER 1991 733


to using only part of the gas to dry the bagasse, only a
portion of the milled bagasse is dried at most factories.
These practices are probably reducing the potential for
recovering heat with bagasse drying.
Bagasse drying requires much auxiliary equipment,
resulting in a larger parasitic energy demand than with the
more conventional methods of heat recovery. Some studies
on bagasse drying have suggested that the large parasitic
load allows for little net exportable energy with flue gas
bagasse drying. However, data compiled in this study
indicate that bagasse dryer systems are, in general, sound
from a net energy standpoint.

ACKNOWLEDGMENTS. This work was performed under the


sponsorship of the United States Agency for International
Development/Tennessee Valley Authority, through a
subcontract from the HSPA. The author gratefully
acknowledges the significant contribution of the members
of the Sugar Technology and Engineering Department of
the HSPA Experiment Station in the preparation of this
report and the valuable guidance of Mr. John Kadyszewski,
Program Manager of the Bioenergy Systems and
Technology Project, Office of Energy, Agency for
International Development. The author also thanks the
various members of the Hawaiian sugar industry who
provided much of the information contained in this report.

REFERENCES
Arrascaeta, A. and P. Friedman. 1987. Bagasse drying.
International Sugar Journal 89:68-71.
Furines, J.H. 1976. Pre-drying bagasse using flue gases. The
Sugar Journal 39:39-40.
Keenliside, B. 1983. A comparison of air pre-heaters and
bagasse drying systems for energy efficiency.
Proceedings of the International Society of Sugar Cane
Technologists, 1508-1516.
Kinoshita, CM. 1988. A theoretical analysis of predrying of
solid fuels with flue gas. Journal of Energy Resources
Technology 110:119-123.
Kinoshita, CM. 1989. Flue-gas drying of bagasse. Report
HNEI89-1003 by the Hawaii Natural Energy Institute
for the Office of Energy of the United States Agency for
International Development/Tennessee Valley Authority
through a subcontract from the Hawaiian Sugar Planters'
Association. Contract No. TV-73595A. Honolulu:
HNEI.
Kinoshita, CM. 1990. Cogeneration in the Hawaiian sugar
Figure 5-Bagasse boiler/dryer stacks with bagasse dryer operating
(white plume, top) vs. not operating (gray plume, bottom).
industry. Report HNEI 90-1002 by the Hawaii Natural
Energy Institute for the Office of Energy of the United
States Agency for International Development/Tennessee
tramp air in and around the dryers. This may be reducing Valley Authority through a subcontract from the
the potential for heat recovery and increasing the fan power Hawaiian Sugar Planters' Association. Contract No. TV-
required to convey the flue gas, the boiler wear rate, and 73595A. Honolulu: HNEI.
the amount of bagasse fines that pass through the cyclone Miller, C F . 1981. Economic study of bagasse dehydration.
system. At all factories studied, substantial and increasing Proceedings of the American Society of Sugar Cane
amounts of the total flue gas produced by the boilers are Technologists, 1978 Meeting, 148-153.
bypassing the dryer systems, due in part to loss in dryer USEPA. 1977. Standards of performance for new stationary
system fan capacity over time, aggravated by greater sources: Revision to reference method 1-8. Federal
infiltration of tramp air into the dryer systems. In addition Register, August 18, Part 11:41754-41789.

734 APPLIED ENGINEERING IN AGRICULTURE

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