This invention relates to systems and methods for increasing chemical reaction rates by varying the binding energy of substrates to these surfaces at resonant frequencies.
Catalytic rate enhancement occurs primarily through catalyst design to tune the binding characteristics of surface species and transition states for maximum catalytic turnover frequency. In the past two decades, advances in nanostructured materials have led to detailed synthesis of atomic-scale active sites that precisely balance the surface substrate binding energies. The limit of this approach is characterized by the Sabatier principle, which states that the binding of substrates must be neither too strong nor too weak. Quantitative description of the Sabatier principle was captured in Balandin-Sabatier volcano-shaped curves, which depicted a metric of catalyst activity relative to a descriptor of substrate binding.
The simplest surface catalytic mechanism of species A reacting to species B depicted in
The asymmetry of some Balandin-Sabatier curves depicted in
In accordance with the Sabatier principle, the characteristics of a single binding site are balanced between at least two transient phenomena, leading to maximum possible catalytic activity at a single, static condition (i.e., a ‘volcano’ peak). Catalyst activity optimization within the context of Balandin-Sabatier curves has focused on catalyst design to achieve optimal turnover at the volcano curve apex. Of the existing catalysts and multi-metal combinations, computational screening of the relevant surface-binding descriptors has aimed to identify single- or multi-descriptor optima from databases of catalytic materials. Other strategies have aimed to create and tune the properties of new materials including physical and electronic descriptors such as metal spacing and coordination, d-band center and fermi level, electronic interaction with supports, solvents, and co-adsorbents via multi-metal mixing, and nanostructured synthesis. All of these approaches have achieved success in creating new materials near the maximum theoretical turnover frequency of a static catalyst. However, some limitations of the Balandin-Sabatier maximum arises at least in part from the multi-purpose catalyst, which must balance the kinetics of competing reaction steps (activation, desorption, etc.).
In a first general aspect, a heterogeneous catalysis method for catalyzing the conversion of a first chemical species to a second chemical species includes varying a binding energy of the first chemical species, the second chemical species, or both over time and in the presence of a catalyst.
Implementations of the first general aspect may include one or more of the following features.
Varying the binding energy over time may include varying a strain of the catalyst over time, varying an electron density of the catalyst over time, periodically varying the binding energy over time, oscillating the binding energy over time, varying the binding energy at a selected frequency and a selected amplitude, varying the binding energy in a selected amplitude range of 0.1 eV to 4.0 eV (e.g., 0.6 eV to 1.5 eV), varying the binding energy at a frequency in a range of 0.0001 Hz to 1011 Hz (e.g., 100 Hz to 107 Hz), simultaneously varying the binding energy at two or more frequencies, varying the amplitude of the binding energy between a maximum and a minimum, varying the amplitude of the binding energy between a maximum, a minimum, and one or more intermediate levels, or any combination thereof. Varying the binding at a selected frequency and a selected amplitude can include applying a selected waveform to the binding energy. The selected waveform can be a square wave, a sinusoidal wave, a triangular wave, a sawtooth wave, or a combination thereof.
Conversion of the first chemical species the second chemical species may include synthesis, reduction, oxidation, dehydrogenation, dehydration, or any combination thereof. The conversion of the first chemical species to the second chemical species can include synthesis of an alkane, an alkene, an alkyne, or an alcohol. In some cases, the conversion of the first chemical species to the second chemical species includes synthesis of ammonia; synthesis of carbon dioxide; synthesis of methanol; synthesis of ethanol; synthesis of carbon monoxide; reduction of NOx; oxidation of ethylene to ethylene oxide; dehydrogenation of ethane to ethylene; dehydrogenation of propane to propylene; dehydrogenation of butane to butenes, butadiene, or both; partial oxidation of methane to methanol; or oxidation of propylene to propylene oxide.
Varying the strain of the catalyst over time may include application of strain or voltage to a piezoelectric material; operatively coupling sound waves to the catalyst; subjecting the catalyst to field effect modulation; applying up to ±3% strain to the catalyst; applying ±0.1% to 0.4% strain to the catalyst; or any combination thereof.
In a second general aspect, a system configured to catalyze the conversion of a first chemical species to a second chemical species incudes a piezoelectric material and a catalyst on the piezoelectric material, wherein the system is configured to apply up to ±3% or ±0.1% to ±0.4% strain to the catalyst over time to vary a binding energy of a first chemical species, a second chemical species, or both.
Implementations of the second general aspect may include one or more of the following features.
The catalyst may be in direct contact with the piezoelectric material or in direct contact with an active metal or oxide supported on the piezoelectric material. The system is configured to provide an electric field of ±1V to ±100 V across the piezoelectric material. The catalyst may include gold, platinum, palladium, copper, iron, nickel, silver, ruthenium, cobalt, manganese, iridium, rhodium, molybdenum, or a combination thereof.
In a third general aspect, a system configured to catalyze the conversion of a first chemical species to a second chemical species includes a sound wave generator or a pressure generator and a catalyst, wherein the sound wave or the pressure generator is configured to provide sound waves or pressure to vary a binding energy of a first chemical species, a second chemical species, or both over time.
Implementations of the third general aspect may include one or more of the following features.
The system may include a support in direct contact with the catalyst. The support may include an active metal or oxide. The sound wave generator may be configured to provide sound waves having a frequency in a range of 0.1 Hz to 107 Hz or 100 Hz to 10,000 Hz.
In a fourth general aspect, a system configured to catalyze the conversion of a first chemical species to a second chemical species includes a back gate device having a dielectric material, a back gate material, and a catalyst, wherein the back gate device is configured to apply a back gate voltage to the catalyst.
Implementations of the fourth general aspect may include one or more of the following features.
The system may include a dielectric support in direct contact with the catalyst. The catalyst may be in the form of a metal layer, a single metal atom, or a metal cluster comprising two or more atoms. The catalyst may have a thickness of less than 10 nm or less than 100 nm. In some cases, the back gate voltage is a waveform (e.g., a square wave, a sinusoidal wave, a sawtooth wave, or a triangular wave). A frequency of the waveform is typically in a range of 0.1 Hz to 107 Hz or 100 Hz to 10,000 Hz. The dielectric material may spontaneously polarize in the presence of an electric field and typically includes a paraelectric material or a ferroelectric material. The ferroelectric material may include one or more of barium titanate (BaTiO3), potassium niobate (KnbO3), lead titanate (PbTiO3), lithium tantalate, strontium titanate (SrTiO3), and doped materials such as BaZrO3/BaTiO3). The paraelectric material may include one or more of silicon dioxide (SiO2), aluminum oxide (Al2O3), and tantalum pentoxide (Ta2O5).
As described herein, a dynamic heterogeneous catalyst oscillating between two electronic states can demonstrate catalytic activity as great as 3-4 orders of magnitude (1,000-10,000×) above the Sabatier maximum. Surface substrate binding energies can be varied (0.1<U<3.0 eV) over a broad range of frequencies (10−4<f <1011 s−1) in square, sinusoidal, sawtooth, and triangular waveforms to characterize the impact of surface dynamics on average catalytic turnover frequency. Catalytic systems are shown to exhibit order-of-magnitude dynamic rate enhancement at ‘surface resonance’ defined as the band of frequencies (e.g., 0.1 to 1011 Hz or 103-107 Hz) where the applied surface waveform kinetics were comparable to kinetics of individual microkinetic chemical reaction steps. Key dynamic performance parameters are described regarding industrial catalytic chemistries and implementation in physical dynamic systems operating above kilohertz frequencies.
The details of one or more embodiments of the subject matter of this disclosure are set forth in the accompanying drawings and the description. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims.
Systems and method for temporally decoupling surface reaction steps via oscillation of the catalytic surface binding energy are described. Heterogeneous catalysts including metals, metal oxides, and microporous materials such as zeolites or metal-organic frameworks (MOFs) can be enhanced in overall activity when operated under dynamic oscillatory conditions. By varying the binding energy of substrates in general to these surfaces at frequencies in the resonance frequency range (from 103-107 Hz) at moderate amplitudes (0.3-1.5 eV), reaction rates can be increased from 10× to over a million times faster than conventional catalysts at static conditions. The waveform of oscillation can take various forms, including square, sinusoidal, sawtooth, and triangular, with an amplitude of binding energy oscillation typically in a range of 0.3 to 1.5 eV.
As shown in
The response of the substrate on the catalyst surface depends on the relative dynamics of the system to the kinetics of the surface steps (i.e., reactions, desorption). For a catalyst oscillating between two states as a square waveform with amplitude of ΔU and frequency (f ˜τ−1), the optimum time-averaged turnover frequency will occur when the time scale of each state is approximately the same as the time scale of the individual surface steps. Referred to here as “surface resonance,” the resonant frequencies depicted in
Dynamic catalysis can be explored for a broad range of catalyst and dynamic applied conditions to understand the connection between catalyst-system design combinations and catalytic turnover frequency. For BEP relations identified in
Continuously stirred tank reactor (CSTR—perfect mixing assumed) models were implemented in Matlab 2017b and Matlab 2018b. The shell code set reactor parameters included the inlet volumetric flow rate ({dot over (q)}), catalyst weight (w), and active site loading. Reactor time-on-stream data was generated using the Matlab ODE15s differential equation solver. This solver was selected based on its performance. The set of differential equations consisted of forward and reverse rates for the consumption of gas phase (A, B) and surface species (*, A*, B*). This general reaction system, A↔B, was modeled using three reversible elementary steps: (i) adsorption of A, (ii) conversion of A* to B*, and (iii) desorption of B.
A
A* (1)
A*
B* (2)
B*
B (3)
Generalized forms of the differential equation used for each gas phase and surface species are:
Reaction rate equations consisted of rate constants, and each elementary step was assumed to be first order in all participating reactants. Since this was modeled as a gas phase reaction, adsorption steps were expressed in terms of A and B pressures (bar).
r
ads
=k
ads
P
A[*] (6)
r
des
=k
des[A]* (7)
r
surf rxn forward
=k
surf fxn forward[A]* (8)
Rate constants were constructed as Arrhenius expressions using pre-exponential factors and activation energies for adsorption, desorption, and surface reactions. Pre-exponential factors were set to 106 (bar-s)−1 for adsorption steps and 1013 s−1 for surface reaction and desorption steps. Activation energy was set to 0 kcal/mol for adsorption and to the binding energies (BEs) of A and B for their respective desorption steps. The binding energies for A and B, the surface reaction activation energy (Ea), and the surface reaction enthalpy of reaction were selected; the base conditions were BEA=30 kcal mol−1, BEB=23 kcal mol−1, Ea=24 kcal mol−1, and ΔH=0 kcal/mol.
Brønsted-Evans-Polyani relationships between Ea and BEs were held at a constant offset of 24 kcal/mol and the slope of the relationship, α, was varied (0≤α≤1.0). Thus, the activation energy was expressed as a linear function of the surface enthalpy of reaction, ΔHS (i.e., the difference in binding energies between A* and B*):
E
a
=α*ΔH
S
+E
0 (9)
Balandin volcano plots were generated by varying ΔHs and measuring the time-averaged turnover frequency (TOF) at 1.0% overall yield of B. Turnover frequency was defined as
for the CSTR design equation, so in practice q was adjusted until the outlet yield of component B was 1.0%. Variation in the BEP slope (0≤α≤1.0) resulted in surface reaction activation energies (15<Ea<34 kcal/mol) between binding energies of 0.5 and 2.0 eV.
Dynamic catalysis was simulated by running ODE15s for a system in which BEs varied with time on stream as either square, sinusoidal, sawtooth, or triangular waves. The shift of the binding energy of B was specified in the shell code and affected the binding energies of A and B as well as the activation energy of the surface reaction. Oscillation period/frequency was set by specifying the time duration spent at each condition. Reported TOFs were calculated when the system oscillation was centered on 1.0% yield and after the reactor had achieved oscillatory steady state, defined as a steady time-averaged turnover frequency.
Plots of the average turnover frequency as a function of surface binding energy oscillation amplitude and frequency (i.e., heat maps) were generated in Matlab 2018b using the jet color scheme to indicate low and high TOF. The shape of the data was assessed using polynomial fits of varying order. 3rd order polynomials were found to fit the data and heat map data consists of interpolated data from a modified akima cubic hermite fit through discrete data points at 0-1.0 eV ΔBE. This data was obtained for symmetric dynamic catalysis starting at the volcano peak (ΔBE=−0.05 to 0.05 eV) and oscillating the same amplitude in each direction (from 0-0.75 eV). Data were also obtained for asymmetric dynamic catalysis where the endpoints were chosen based on extrapolated linear fits of each side of the volcano curve. These lines were set equal with a specified oscillation amplitude between 0-1.5 eV, and the endpoints were chosen by drawing a vertical line down to the volcano plot. Frequency response figures were generated for scenarios with varying BEP relationships where the BEP slope ranged from zero to one.
The impact of oscillating the surface binding energy of B* with time is depicted in
The TOFB of
The impact of the surface state-flipping frequency on the time-averaged turnover frequency is depicted in
For the volcano curve system depicted in
An interpretation of catalytic surface resonance comes from evaluating the TOFB response of each condition independently, as shown in
Variation of the surface square waveform amplitude changes the kinetics of the surface chemistry, resulting in a shift of the resonance frequency band. As depicted in the heat map of
The ability to dynamically accelerate catalytic turnover depends at least in part on the energetics of the obtainable states defined by the shape of the Balandin-Sabatier volcano curve. Of the many parameters that define the volcano shape, the linear-scaling relationship parameter, a, relating the surface reaction enthalpy to the surface reaction enthalpy can dramatically shift the slope of the volcano plot. While
A broader volcano of a of 0.4 in
Applying dynamic operation to heterogeneous catalytic applications include identifying the conditions of optimal performance in addition to new design variables such as surface waveform shape that can be implemented in reactor technology. As depicted in
Implementation of dynamic operation of heterogeneous catalysts includes the capability to modify the binding energy of surface intermediates with time. Based on the simulations of
Device construction for tuning of the surface intermediate adsorbate binding energy can be interpreted via the electronic state of the catalyst material. Surface intermediates such as adsorbed nitrogen, N*, correlate linearly with the d-band edge/center when compared across a broad range of metals. Temporal variation of metal d-bands exists in at least two categories including electronic and physical (and even electro-mechanical) manipulation. Straining of surfaces has been shown to shift the d-band centers of metals, metal alloys and other 2D materials, which alters the binding energy of adsorbates such as carbon monoxide. When combined with dynamic approaches such as sound waves or piezoelectrics capable of 1% strain oscillation exceeding, for example, kilohertz frequencies, this approach can provide the frequencies and amplitudes for resonant dynamic catalytic acceleration. Other appropriate methods can be used to electronically manipulate a catalyst surface including field effect modulation or non-Faradaic electrochemical modification, both of which are suitable to achieve the frequency and amplitude targets desired for surface catalytic resonance. Examples of systems suitable for implementing dynamic catalysis for conversion of gaseous, vaporous, or liquid chemicals on catalytic surfaces are depicted in
Chemistries that can be accelerated via dynamic catalysis and oscillatory surface energy include any surface reaction that has the ability to vary surface intermediate binding energy leading to a shift in overall reaction rate limitation between surface reactions and product desorption. Examples of suitable reactions are provided below, along with examples of appropriate catalysts, conditions, and parameters for dynamic operation including surface binding energy [eV], waveform type, and frequency [Hz].
Ammonia Synthesis. To enhance the overall catalytic rate, application of methods including piezoelectric strain, sound waves, or field effect modulation can be conducted during ammonia synthesis including the reaction of N2 and H2 to make NH3. The reaction can be conducted on supported Ru metal with an oscillation frequency >10 Hz and an oscillation amplitude of 0.7-1.5 eV according to the Balandin volcano for ammonia synthesis. Square, sinusoidal, and triangle waveforms can be implemented, for example, at 400° C., 50 bar total inlet pressure, and 3:1 H2:N2.
NOx Reduction. To convert gaseous nitrogen oxides to N2 using hydrogen, ammonia, or hydrocarbon co-reactants, NOx reduction can be conducted under the application of methods including piezoelectric strain, sound waves, or field effect modulation. NOx reduction may occur on supported oxide catalysts including V2O5 and TiO2 with an oscillation frequency >0.001 Hz and oscillation amplitude of 0.75-1.5 eV. Square, sinusoidal, and triangle waveforms can be implemented, for example, at 110° C., 1 atm total pressure, and a 1:1 NO: reducing agent molar ratio.
Ethylene Oxidation to Ethylene Oxide. To oxidize ethylene to ethylene oxide with O2 with rates accelerated, dynamic catalysis can be conducted using methods including piezoelectric strain, sound waves, or field effect modulation during ethylene oxidation conducted on supported Ag catalysts with an oscillation frequency >10 Hz and an oscillation amplitude of 0.75 to 1.5 eV. Square, sinusoidal, and triangle waveforms can be implemented, for example, at 50 psig and 250° C.
Ethane Dehydrogenation to Ethylene. Ethane vapor can be dehydrogenated to valuable polyethylene monomer and hydrogen (H2) using methods including piezoelectric strain, sound waves, and field effect modulation. Dehydrogenation can proceed, for example, on oxide catalysts including vanadium and molybdenum oxide, metal catalysts including supported Pt and Pt—Sn, and nitride catalysts including boron nitride (BN). A dynamic oscillation frequency >0.001 Hz can be implemented with an oscillation amplitude of 0.5-1.5 eV. Dynamics with square, sinusoidal, and triangle waveforms can be implemented, for example, at 1-5 atm and 500-600° C.
Propane Dehydrogenation to Propylene. Propane dehydrogenation to valuable polypropylene monomer and hydrogen (H2) can be conducted using methods including piezoelectric strain, sound waves, and/or field effect modulation. Dehydrogenation may be facilitated by supported Pt catalysts and/or Pt alloys with Sn or Au. Dynamic catalysis can be conducted, for example, with an oscillation frequency >0.005 Hz and an oscillation amplitude between 0.5-1.5 eV. Dynamics with square, sinusoidal, and triangle waveforms can be employed, for example, at 1 atm feed pressure between 550-620° C.
Butane Dehydrogenation to Butenes and/or Butadiene. Butane vapor can be dehydrogenated to butenes and further to highly desired rubber component butadiene with dynamic catalysis, using methods including piezoelectric strain, sound waves, and field effect modulation. Dehydrogenation can proceed over pure and mixed vanadium oxide catalysts with, for example, dynamic oscillation frequencies >0.007 Hz and oscillation amplitudes between 0.7-1.5 eV. Square, sinusoidal, and triangle waveforms can be employed, for example, at 1-2 atm feed pressure between 500-540° C.
Methane Partial Oxidation to Methanol. Widely available methane (natural gas) can be converted to methanol (a desirable platform molecule) using oxygen, peroxides, or ozone with methods including piezoelectric strain, sound waves, and field effect modulation. Supported Ni and other transition metal catalysts can be used, for example, with an oscillation frequency >400 Hz and an oscillation amplitude between 0.6-1.5 eV. Square, sinusoidal, and triangle waveforms can be implemented, for example, at 1-300 atm feed pressure between 450-900° C.
Propylene Oxidation to Propylene Oxide. Propylene vapor can be oxidized to propylene oxide (a valuable precursor to propylene glycol and polypropylene glycol) using oxygen, peroxides, or ozone with methods including piezoelectric strain, sound waves, and field effect modulation. Noble metal catalysts such as supported Pt and oxide catalysts including, for example, supported TiOx, NbOx, and TaOx can be employed dynamically with an oscillation frequency >0.1 Hz and amplitude between 1.3-3.0 eV. Sinusoidal, sawtooth, and triangle waveforms can be implemented, for example, under reaction conditions including 5-25 bar inlet pressure and 150-300° C.
Other examples of implementation of dynamic catalysis are listed in Table 1. All dynamic examples can be conducted with square, sinusoidal, sawtooth, or triangular waveforms in catalyst surface binding energy.
Various implementations are described below.
An experimental method, including a reactor and heterogeneous catalyst, the method comprising perturbation of catalyst properties as a function of time on stream leading to variation in binding energy of one or more of the surface species. The heterogeneous catalyst may be provided with a specified oscillation frequency and amplitude.
An experimental method comprising oscillation of heterogeneous catalyst properties with specification including one or more of: oscillation of catalyst binding energy by 0.6-1.5 eV or 0.1 to 4.0 eV, oscillation at a dynamic speed of 0.0001-1011 Hz or 100-10,000,000 Hz, a selected waveform (e.g., square wave, sinusoidal, triangular, sawtooth); oscillation between more than two states (e.g., 3, 4, 5, or more states). For systems with more than one state, the amplitude may vary for each state. The waveform may include a combination of frequencies (e.g., 1,000 Hz and 10,000 Hz overlapping).
An experimental method, performed on an apparatus including a reactor and piezoelectric material, the method comprising dynamic application of strain or voltage to the piezoelectric material, with a catalytic reaction performed on the piezoelectric material or an active metal or oxide phase supported on the piezoelectric material.
An experimental method, performed on an apparatus including a reactor and lead zirconate titanate (PZT) piezoelectric, the method comprising application of ±0.1 to 0.4% strain as a function of time on stream or up to 3% strain. The catalysis may occur over Au, Pt, Pd, Cu, Fe, Ni, Ag, Ru, Co, Mn, Ir, Rh, Mo, or a combination thereof supported on the PZT piezoelectric An electric field applied across the piezoelectric can be between 0.001 to 10 V/A.
An experimental method, performed on an apparatus including a reactor and an acoustic device, the method comprising one or more of dynamic application of sound waves or pressure from the acoustic device to the catalyst, the support material, or both; catalytic reaction performed on catalyst material being subjected to sound waves; and active metal or oxide phase or both supported on the support being subjected to sound waves. Sound wave frequencies can be applied in a various forms and frequencies (e.g., 100 Hz to 10,000 Hz or 0.1 Hz to 10,000,000 Hz)
An experimental method, performed on an apparatus consisting of a reactor and an electronically back-gated material setup includes dynamic application of back gate voltage to the catalytic stack including a dielectric and back-gate material optionally with a catalyst in contact with the dielectric. The dielectric may be a paraelectric or ferroelectric material that spontaneously polarizes in the presence of an electric field. Examples of suitable ferroelectric materials include barium titanate (BaTiO3), potassium niobate (KnbO3), lead titanate (PbTiO3), lithium tantalate, strontium titanate (SrTiO3), and doped materials such as BaZrO3/BaTiO3. Examples of suitable paraelectric materials include silicon dioxide (SiO2), aluminum oxide (Al2O3), and tantalum pentoxide (Ta2O5). The catalysts may include a metal layer, single metal atoms, or metal cluster of 2 or more atoms. In some cases, the catalyst layer/cluster may be <10 nm or <100 nm in thickness. The catalyst may include a catalyst layer, cluster, or single atoms of metals, metal monolayers, bimetallic layers, metal oxide layers, oxide clusters, or porous layers such as zeolites or porous clusters. The catalytic reaction occurs on the catalyst material. The applied backgate voltage is a dynamic waveform (e.g., square, sinusoidal, triangle, sawtooth), with frequencies in a range of 0.1 Hz to 10,000,000 Hz or 100 Hz to 10,000 Hz.
Although this disclosure contains many specific embodiment details, these should not be construed as limitations on the scope of the subject matter or on the scope of what may be claimed, but rather as descriptions of features that may be specific to particular embodiments. Certain features that are described in this disclosure in the context of separate embodiments can also be implemented, in combination, in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments, separately, or in any suitable sub-combination. Moreover, although previously described features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can, in some cases, be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.
Particular embodiments of the subject matter have been described. Other embodiments, alterations, and permutations of the described embodiments are within the scope of the following claims as will be apparent to those skilled in the art. While operations are depicted in the drawings or claims in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed (some operations may be considered optional), to achieve desirable results.
Accordingly, the previously described example embodiments do not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure.
This application claims the benefit of U.S. Patent Application No. 62/812,146 entitled “DYNAMIC RESONANCE OF HETEROGENEOUS CATALYSIS” and filed on Feb. 28, 2019, which is incorporated herein by reference in its entirety.
This invention was made with government support under DE-SC0001004 awarded by the U.S. Department of Energy—Energy Frontier Research Center. The government has certain rights in the invention.
Filing Document | Filing Date | Country | Kind |
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PCT/US2020/020282 | 2/28/2020 | WO | 00 |
Number | Date | Country | |
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62812146 | Feb 2019 | US |