Pre-Grinder (Roller Press / Vertical Roller Mill) with...
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Proposed Modernization & Expansion of Cement Production Capacity (0.792 MTPA to 0.990 MTPA) by installation of
Pre-Grinder (Roller Press / Vertical Roller Mill) with Existing Cement Ball Mill (No Increase in Clinker Production)
At Village Lumshnong, Tehsil Khliehriat, District East Jaintia Hills (Meghalaya) Pre- feasibility Report
Star Cement Ltd. 1
PRE-FEASIBILITY REPORT
1.0 EXECUTIVE SUMMARY
Star Cement Ltd. (formerly Cement Manufacturing Company Ltd.), has an existing Cement Plant
having Clinker/Cement production capacity of 0.792 MTPA as per EC vide letter no.
SEIAA/PROJECT-6/2008/23 dated 16th March, 2010 at Village Lumshnong, Tehsil Khliehriat, District
East Jaintia Hills (Meghalaya).
The companyis now proposing Modernization &Expansion of Cement Production Capacity (0.792
MTPA to 0.990 MTPA) by installation of Pre-grinder (Roller press/Vertical Roller Mill) with existing
Cement Ball mill (No increase in Clinker production) at Village Lumshnong, Tehsil Khliehriat,
District East Jaintia Hills (Meghalaya). There is no increase in clinker production.
Table -1
Salient Features of the Project
S. NO. PARTICULARS DETAILS
A. Nature & Size of the Project Proposed Modernization &Expansion of Cement Production Capacity (0.792 MTPA to 0.990 MTPA) by installation of Pre-grinder (Roller Press/ Vertical Roller Mill) with existing Cement ball mill (No increase in Clinker production) at Village Lumshnong, Tehsil Khliehriat, District East Jaintia Hills (Meghalaya)
B. Category of the Project Category “B” (As per EIA Notification dated 14th Sept., 2006 and as amended from time to time; General Condition (GC) is applicable in any project or activity if any Wildlife Sanctuary fall within 5 km radius of the periphery of the project or activity. Cement Plant is falling under 5 km radius of Narpuh Wildlife Sanctuary (4.5 km in SE direction) therefore; this expansion project will be treated as Category ‘A’.
C. Location Details
Village Lumshnong
Tehsil Khliehriat
District East Jaintia Hills
State Meghalaya
Latitude 250 10’ 36.59”
Longitude 920 23’ 25.53”
Toposheet No. 83 C/8 (Restricted)
D. Area Details
Total Plant Area 35 ha
Greenbelt / Plantation Area (ha)
11.9ha i.e. approx. 33 % of total plant area has already been developed under greenbelt / plantation; same will be maintained.
E. Environmental Setting Details (with approximate aerial distance & direction from the plant site)
1. Nearest Town / City Khliehriat (approx. 20 km in North direction)
Shillong (approx. 66 km in NW direction)
2. Nearest National Highway / State Highway
NH-44 (0.5 km in South direction)
3. Nearest Railway station Bihara Railway Station (approx. 35 km aerial distance & 73 km
Proposed Modernization & Expansion of Cement Production Capacity (0.792 MTPA to 0.990 MTPA) by installation of
Pre-Grinder (Roller Press / Vertical Roller Mill) with Existing Cement Ball Mill (No Increase in Clinker Production)
At Village Lumshnong, Tehsil Khliehriat, District East Jaintia Hills (Meghalaya) Pre- feasibility Report
Star Cement Ltd. 2
S. NO. PARTICULARS DETAILS
distance by road in SE direction from the plant site)
4. Nearest Airport Silchar (approx. 66 km in SE direction)
5. National Parks, Wildlife Sanctuaries, Biosphere Reserves within 10 km radius
Narpuh Wildlife Sanctuary (approx. 4.5 km in SE direction)
6. Reserve Forests (RF) / Protected Forests (PF) within 10 km radius
Narpuh Reserve Forest (approx. 9.0 km in SE direction)
7. River / Water Body (within 10 km radius)
Umtyrngai Nalla(Adjacent to the plant)
Um-Lunar River (4.0 km East direction)
Lubha River (4.5 km in SE direction)
8. Seismic Zone Zone - V [as per IS 1893 (Part-1): 2002]
F. Cost Details
Total Cost of the Expansion Project
Rs. 62 Crores
Cost for Environment Management Plan
o Capital Cost -Rs. 2.0 Crores
o Recurring Cost - Rs. 0.10 Crores/annum.
G. Basic Requirements for the project
Existing Additional for proposed expansion
Total after proposed expansion
Water Requirement (KLD) 440 10 450
Source: Ground/Surface Water for Colony and Surface Water from Umtyrngai Nalla for Cement Plant.
Power Requirement (MW) 12.5 3.0 15.5
Source: MPL (Meghalaya Power Limited)
Man Power Requirement 130 15 145
Source: Local Area/ Non Local Area
2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
(i) Identification of Project and Project Proponent
Star Cement Limited (formerly Cement Manufacturing Company Ltd.) is the largest cement
manufacturer in north east India. The plant is located at Lumshnong, 125 kms from Shillong
spreading over 35 ha of land. It is a professionally managed and well established cement
manufacturing company enjoying the confidence of consumers because of its superior
quality product and excellent customer service. The company is running cement plants and
mine with latest eco-friendly technology. The plant power requirement is supplied from
subsidiary power plant of MPL (Meghalaya Power Limited). Plant has a strategic location at
Meghalaya that ensures easy availability of high-grade limestone. Our brand “Star Cement”
has established itself as the most accredited brand of the region on grounds of both quality
and fair pricing.
Proposed Modernization & Expansion of Cement Production Capacity (0.792 MTPA to 0.990 MTPA) by installation of
Pre-Grinder (Roller Press / Vertical Roller Mill) with Existing Cement Ball Mill (No Increase in Clinker Production)
At Village Lumshnong, Tehsil Khliehriat, District East Jaintia Hills (Meghalaya) Pre- feasibility Report
Star Cement Ltd. 3
(ii) Brief description of nature of the project
Star Cement Ltd.,(formerly Cement Manufacturing Company Ltd.) has an existing Cement
Plant having Clinker/Cement Production Capacity of 0.792 MTPA as per EC letter no.
SEIAA/PROJECT-6/2008/23 dated 16th March, 2010 at Lumshnong, Khliehriat District: East
Jaintia Hills (Meghalaya).
The company is now proposing Expansion of Cement Production Capacity (0.792 MTPA to
0.990 MTPA) by installation of Pre-grinder (Roller Press/ Vertical Roller Mill) with existing
Cement ball mill (No increase in Clinker production) at Village Lumshnong, Tehsil Khliehriat,
District East Jaintia Hills (Meghalaya) under Section 7(ii) of EIA Notification, 2006. There is
no increase in clinker production.
The current plant is a ball mill based plant and proposes to install a pre-grinder for the
cement mill which would enhance its capacity from 0.792 MTPA to 0.99 MTPA. The
enhancement in cement production would lead to increase utilization of fly ash.
A compact and energy-efficient semi-finish grinding system shall be installed which will
receive the fresh feed from the existing feed hoppers, process it and supply semi-finished
material to the existing ball mill. The pre-grinder and existing ball mill will operate in closed
circuit with two separators. The static separator shall be dis agglomerating and feed the
coarse material to the pre-grinder, and the dynamic separator shall separate out the
finished product and feed the coarse material to the existing ball mill.
Details of the products with capacities are given as:
S. No.
Product
Existing Capacity as per EC
(MTPA)
Additional capacity
(MTPA)
Total capacity after proposed
expansion (MTPA)
1. Clinker 0.792 Nil 0.792
2. Cement 0.792 0.198 0.990
Screening category: Category “B” (As per EIA Notification dated 14th Sept., 2006 and as
amended from time to time; General Condition (GC) is applicable in any project or activity if
any Wildlife Sanctuary fall within 5 km radius of the periphery of the project or activity.
Cement Plant is falling under 5 km radius of Narpuh Wildlife Sanctuary (4.5 km in SE
direction) therefore; this expansion project will be treated as Category ‘A’.
(iii) Need for the project and its importance to the country and or region
Indian cement industry is large, growing and with consumption of 185kg/capita/yr in 2011
(compared to global average of ~300 kg/capita/year) the country itself has the capacity to
demand significantly more cement as it develops.
In addition to the large raw material deposits, the strategic location of Meghalaya,
proximity to large markets in North eastern part of India, and proximity to national
Proposed Modernization & Expansion of Cement Production Capacity (0.792 MTPA to 0.990 MTPA) by installation of
Pre-Grinder (Roller Press / Vertical Roller Mill) with Existing Cement Ball Mill (No Increase in Clinker Production)
At Village Lumshnong, Tehsil Khliehriat, District East Jaintia Hills (Meghalaya) Pre- feasibility Report
Star Cement Ltd. 4
highway(providing an opportunity to cater to these markets) passing through the State,
have made Meghalaya an ideal destination for establishing cement units.
Now with the government of India giving push to various infrastructure projects, housing
facilities and road networks, Hydropower, the cement industry in India is currently growing
at an enviable pace and further growth in the Indian cement industry is expected in the
coming years. Therefore, there is an urgent need to increase the production capacity in the
country.
Hence, the proposal for expansion of Cement Plant by Star Cement Ltd., will cater the
increasing demand of cement in the country and region of Meghalaya.
(iv) Demand-Supply Gap
India's cement demand is expected to reach 550-600 MTPA by 2025. Demand - Supply
projection for cement on National and State basis reveals that there exists an imbalance
between availability and demand of cement particularly in southern and eastern region.
Under these circumstances to bridge the gap, Star Cement Ltd., has proposed to expand
the capacity of existing cement plant at Lumshnong, Meghalaya.
(v) Import vs. Indigenous Production / Export Possibility
Imports are not feasible. Cement produced in the state will be consumed domestically.
(vi) Domestic/ Export Markets
Marketing areas will be Meghalaya, West Bengal, Assam, Nagaland, Manipur, Mizoram,
Tripura & Sikkim; and the mode of transportation for final product will be by road.
(vii) Employment Generation (Direct and Indirect) due to the project
Direct and indirect employment will be generated due to the project. The total manpower
requirement for the project will be 145 persons. Manpower will be sourced from the local
area in Meghalaya state.
3.0 PROJECT DESCRIPTION
(i) Type of Project including interlinked and independent projects, if any.
Star Cement Ltd., (formerly Cement Manufacturing Company Ltd.) is proposing
Modernization & Expansion of Cement Production Capacity (0.792 MTPA to 0.990 MTPA) by
installation of Pre-grinder (Roller Press/ Vertical Roller Mill) with existing Cement ball mill
(No increase in Clinker production) at Village Lumshnong, Tehsil Khliehriat, District East
Jaintia Hills (Meghalaya) under Section 7(ii) of EIA Notification, 2006.There is no increase in
clinker production.
Interlinked Projects: There is no interlinked project.
Independent Projects: There is no independent project.
(ii) Location (map showing general location, specific location, and project boundary & project
site layout) with coordinates
Proposed Modernization & Expansion of Cement Production Capacity (0.792 MTPA to 0.990 MTPA) by installation of
Pre-Grinder (Roller Press / Vertical Roller Mill) with Existing Cement Ball Mill (No Increase in Clinker Production)
At Village Lumshnong, Tehsil Khliehriat, District East Jaintia Hills (Meghalaya) Pre- feasibility Report
Star Cement Ltd. 5
Figure1: Location Map
Proposed Modernization & Expansion of Cement Production Capacity (0.792 MTPA to 0.990 MTPA) by installation of
Pre-Grinder (Roller Press / Vertical Roller Mill) with Existing Cement Ball Mill (No Increase in Clinker Production)
At Village Lumshnong, Tehsil Khliehriat, District East Jaintia Hills (Meghalaya) Pre- feasibility Report
Star Cement Ltd. 6
Figure 2: Plant Layout
Proposed Modernization & Expansion of Cement Production Capacity (0.792 MTPA to 0.990 MTPA) by installation of Pre-Grinder (Roller Press / Vertical Roller Mill) with Existing Cement Ball Mill
(No Increase in Clinker Production)
At Village Lumshnong, Tehsil Khliehriat, District East Jaintia Hills (Meghalaya) Pre- feasibility Report
Star Cement Ltd. 7
Figure 3: Key Plan
Proposed Modernization & Expansion of Cement Production Capacity (0.792 MTPA to 0.990 MTPA) by installation of
Pre-Grinder (Roller Press / Vertical Roller Mill) with Existing Cement Ball Mill (No Increase in Clinker Production)
At Village Lumshnong, Tehsil Khliehriat, District East Jaintia Hills (Meghalaya) Pre- feasibility Report
Star Cement Ltd. 8
(iv) Details of alternative sites consideration and basis of selecting the proposed site,
particularly the environmental considerations gone into should be highlighted.
The proposed expansion will be done out within the existing plant premises, hence, no
alternative site has been considered.
(v) Size or magnitude of operation
The company is now proposing Modernization & Expansion of Cement Production Capacity
(0.792 MTPA to 0.990 MTPA) by installation of Pre-grinder (Roller Press/ Vertical Roller Mill)
with existing Cement ball mill (No increase in Clinker production) at Village Lumshnong,
Tehsil Khliehriat, District East Jaintia Hills (Meghalaya) under Section 7(ii) of EIA Notification,
2006.There is no increase in clinker production.
Screening category: Category “B” (As per EIA Notification dated 14th Sept., 2006 and as
amended from time to time; General Condition (GC) is applicable in any project or activity if
any Wildlife Sanctuary fall within 5 km radius of the periphery of the project or activity.
Cement Plant is falling under 5 km radius of Narpuh Wildlife Sanctuary (4.5 km in SE
direction) therefore; this expansion project will be treated as category ‘A’.
The process includes basic raw material requirement, sizing of equipment, utilities &
services, infrastructure facilities & sources of waste generation, their quantity, treatment &
safe disposal of the waste.
(vi) Project description with process details (a schematic diagram/ flow chart showing the
project layout, components of the project etc. should be given)
Process Details
The Manufacturing Process details comprises of:
� Clinker handling
� Fly ash handling
� Gypsum storage & handling
� Cement production and storage
� Cement packing and dispatch.
Clinker handling: Clinker is already being produced at plant site itself and stored in silos.
From the silo, clinker is being conveyed to hopper and extracted back for the grinding
process by a combination of weigh feeders and belt conveyors.
Fly ash handling: Fly ash from source is being transported through Pneumatic conveying and
extraction arrangement comprises of weigh feeders and conveyer belts and fed to cement
mill.
Gypsum storage & handling: Gypsum received by road and stored in a covered shed. Gypsum
is extracted by combination of weigh feeders and conveyer belt.
Proposed Modernization & Expansion of Cement Production Capacity (0.792 MTPA to 0.990 MTPA) by installation of
Pre-Grinder (Roller Press / Vertical Roller Mill) with Existing Cement Ball Mill (No Increase in Clinker Production)
At Village Lumshnong, Tehsil Khliehriat, District East Jaintia Hills (Meghalaya) Pre- feasibility Report
Star Cement Ltd. 9
Cement Production:
i) Current Status
As per the existing system the fresh feed i.e. clinker, fly ash and gypsum are fed to the ball
mill where it is grinded into final product cement and the discharge from the ball mill is
passed through separator and the mill is operated in closed circuit. The output of the
cement mill is fed into the separator and in the separator the coarser material is separated
and resent to the ball mill and the finer product is taken as final product and sent to the
cement silo. The clinker which is fed into the cement mill consists of granules up to the size
of 30-40 mm and the output of the cement mill consists of fine cement of approximately
3000 blaines. The basic existing ball mill circuit is as shown below.
EXISTING BALL MILL CIRCUIT
ii) After Up gradation
A compact and energy-efficient semi-finish grinding system (Roller Press /Vertical Roller
Mill) shall be installed which will receive the fresh feed from the existing feed hoppers,
process it and supply semi finished material to the existing ball mill. The High Pressure
Grinding Roller mill /VRM (Pre Grinder) and existing ball mill will operate in closed circuit
with two separators. The static separator shall be dis agglomerating and feed the coarse
material to the pre-grinder, and the dynamic separator shall separate out the finished
product and feed the coarse material to the existing ball mill.
Proposed Modernization & Expansion of Cement Production Capacity (0.792 MTPA to 0.990 MTPA) by installation of
Pre-Grinder (Roller Press / Vertical Roller Mill) with Existing Cement Ball Mill (No Increase in Clinker Production)
At Village Lumshnong, Tehsil Khliehriat, District East Jaintia Hills (Meghalaya) Pre- feasibility Report
Star Cement Ltd. 10
CIRCUIT AFTER MODIFICATION WITH ROLLER PRESS/VRM
With High Pressure Grinding, the grinding pressure is transferred from hydraulic system via the
movable roller to the material bed and absorbed in a stable, closed machine frame.
The main advantages of the Pre Grinder system are:
1. Reduction in specific power consumption/tonne of cement. In the Cement Grinding section
the power consumption will reduce from 39 KWh/tonne to 30 KWh/tonne for OPC and from
34 KWh/tonne to 27 KWh/tonne for PPC.
2. Reduction in Noise level
3. No requirement of process water
4. Lower foot print for similar production through ball mill.
Cement Packing and Dispatch: Rotary packer has been installed which receives cement from the
bin, and which is being/will be used for packing of cement. Loading of packed bags on trucks shall
be done by truck loading machines being worked on by operators. One more rotary packer along
with 2 truck loaders will be installed to take care of the increased production.
Proposed Modernization & Expansion of Cement Production Capacity (0.792 MTPA to 0.990 MTPA) by installation of
Pre-Grinder (Roller Press / Vertical Roller Mill) with Existing Cement Ball Mill (No Increase in Clinker Production)
At Village Lumshnong, Tehsil Khliehriat, District East Jaintia Hills (Meghalaya) Pre- feasibility Report
Star Cement Ltd. 11
Project Layout
(vii) Raw material required along with estimated quantity, likely source, marketing area of final
products, mode of transport of raw material and finished product.
(a) Raw Material Requirement
S. No.
Name of Raw
Material
Quantity (TPD) Source Distance & Mode of Transportation
No. of trips after
expansion
For 2400 TPD
Additional For 3000 TPD
1. Clinker 1800 450 2250 CMCL Conveyor belts -
2. Fly Ash 576 144 720 Our subsidiary power plant
located adjoining to the cement
plant
Pneumatic conveying
720 m
-
3. Gypsum 24 06 30 Bhutan 500 km by trucks of 15 Ton capacity
01 truck / day
(b) Marketing Area and Mode of transportation of Final Product
Marketing areas will be Meghalaya, West Bengal, Assam, Nagaland, Manipur, Mizoram,
Tripura & Sikkim; and the mode of transportation for final product will be by road.
Proposed Modernization & Expansion of Cement Production Capacity (0.792 MTPA to 0.990 MTPA) by installation of
Pre-Grinder (Roller Press / Vertical Roller Mill) with Existing Cement Ball Mill (No Increase in Clinker Production)
At Village Lumshnong, Tehsil Khliehriat, District East Jaintia Hills (Meghalaya) Pre- feasibility Report
Star Cement Ltd. 12
Finished goods Transportation
S. No. Description Product Qty (TPD)
1. Existing Cement & Surplus clinker 3000
2. After up gradation Cement& surplus clinker 3150
There is a marginal increase in transportation of finished goods after expansion of the project.
(viii) Resources optimization/ recycling and reuse envisaged in the project, if any, should be
briefly outlined.
o Dust collected from air pollution control equipment is being / will be recycled into the
process.
o Water used for cooling is being / will be partially subjected to evaporation and
partially recycling and hence, no wastewater will be discharged from the plant
premises.
o Domestic wastewater (240 KLD) generated from the colony is being/ will be treated
in STP and the treated water will be utilized for greenbelt development / plantation.
(ix) Availability of water it’s source, energy /power requirement and source should be given.
(a) Water Requirement and Source
Existing water requirement is 440 KLD (plant + colony) and 10 KLD of additional water is
required for expansion project. Total water requirement after expansion project will be 450
KLD.
Source: Ground /Surface Water for Colony and Surface Water from Umtyrngai Nalla for
Cement Plant.
Water Break-Up
Purpose Requirement (KLD)
Existing Additional Total after expansion Source
Cement Plant 150 Nil 150 Surface water
Colony 290 10 300 Tube well/Surface water
TOTAL 440 10 450
(b) Power Requirement and Source
Existing power requirement is 12.5 MW and additional 3.0 MW is required for the proposed
expansion thus, total 15.5 MW will be required for expansion project which will be sourced
from MPL (Meghalaya Power Limited).
(x) Quantity of waste to be generated (liquid and solid) and scheme for their
management/disposal
o Water used for cooling is being / will be partially subjected to evaporation and
partially recycling and hence, no wastewater will be discharged from the plant
premises.
Proposed Modernization & Expansion of Cement Production Capacity (0.792 MTPA to 0.990 MTPA) by installation of
Pre-Grinder (Roller Press / Vertical Roller Mill) with Existing Cement Ball Mill (No Increase in Clinker Production)
At Village Lumshnong, Tehsil Khliehriat, District East Jaintia Hills (Meghalaya) Pre- feasibility Report
Star Cement Ltd. 13
o Domestic wastewater (240 KLD) generated from the colony is being/ will be treated
in STP and the treated water will be utilized for greenbelt development / plantation
and Dust Suppression at Plant & Mines.
o Dust collected from the APCEs is being / will be totally recycled to the process.
o Sludge generated from STP is being/will be used as manure in greenbelt
development/ plantation.
o Used oil and grease is being / will be generated, which is being / will be stored at
separate storage areas designated and maintained as per Hazardous and Other
Wastes (Management and Trans boundary Movement) Rules, 2016 and is being / will
be sold to the CPCB authorized recycler.
4.0 SITE ANALYSIS
(i) Connectivity
The site is well connected to NH-44 (approx. 0.5 km in South direction from the plant site).
Nearest city is Shillong (approx. 66 km in NW direction from the plant site). Nearest Railway
station is Bihara Railway Station (approx. 35 km aerial distance & 73 km distance by road in
SE direction from the plant site). Nearest Airport Silcharis approx. 66 km in SE direction
from the plant site. The site is well connected with communication facilities like telephone,
fax, wireless and as such, no constraints are envisaged in this aspect as the tehsil and district
headquarters are near to the site.
(ii) Land from Land use and Land ownership
Existing plant area is 35 ha and the proposed expansion will be done within the existing
premises; hence, no additional land is required for the proposed expansion project.
Table - 4
Plant Area Break-Up
Particulars Existing Area (ha) Area after expansion (ha)
Cement Plant &Raw Material Storage
12.1 12.2
Colony 2.6 2.6
Greenbelt / Plantation 11.9 11.9
Roads & Nallah 2.8 2.8
Open Area 5.6 5.5
TOTAL 35.0 35.0
(iii) Topography
The topography of the area is undulating. The general drainage is parallel to sub parallel.
The drainage in surrounding area is dendritic in nature and the drainage density depicts a
low drainage density.
Proposed Modernization & Expansion of Cement Production Capacity (0.792 MTPA to 0.990 MTPA) by installation of
Pre-Grinder (Roller Press / Vertical Roller Mill) with Existing Cement Ball Mill (No Increase in Clinker Production)
At Village Lumshnong, Tehsil Khliehriat, District East Jaintia Hills (Meghalaya) Pre- feasibility Report
Star Cement Ltd. 14
(iv) Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area
under CRZ)), shortest distances from the periphery of the project to periphery of the
forests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from
the HFL of the river), CRZ. In case of notified industrial area, a copy of the Gazette
notification should be given
Table - 5
Environmental Settings of the Area
S. NO.
PARTICULARS DETAILS
(with approximate aerial distance & direction from the plant site)
1. Nearest Town / City Khliehriat (approx. 20 km in North direction)
Shillong (approx. 66 km in NW direction)
2. Nearest National Highway / State Highway
NH-44 (0.5 km in South direction)
3. Nearest Railway station Bihara Railway Station (approx. 35 km aerial distance & 73 km distance by road in SE direction from the plant site)
4. Nearest Airport Silchar (approx. 66 km in SE direction)
5. National Parks, Wildlife Sanctuaries, Biosphere Reserves within 10 km radius
Narpuh Wildlife Sanctuary (approx. 4.5 km in SE direction)
6. Reserve Forests (RF) / Protected Forests (PF) within 10 km radius
Narpuh Reserve Forest (9.0 km in SE direction)
7. River / Water Body (within 10 km radius) Umtyrngai Nalla(Adjacent to plant)
Um-Lunar River (4.0 km in East direction)
Lubha River (4.5 km in SE direction)
8. Seismic Zone Zone - V [as per IS 1893 (Part-1): 2002]
(v) Existing Infrastructure
Total plant area is 35 ha and the proposed expansion will be done within the existing plant
premises area.
o Workshop
A common mechanical and electrical workshop is located to take care of the regular
maintenance/ repair jobs in the plant.
o Machinery stores
A store building needed for storing tools, spare parts, consumables, etc. is available.
o Cranes, Monorails and Pulley blocks
Adequate sized maintenance cranes, monorails and pulley blocks at all suitable locations at
the plant for ease of maintenance and operation.
o Time and Security office
At the entrance of the main plant, a time office and a security office has been constructed.
Proposed Modernization & Expansion of Cement Production Capacity (0.792 MTPA to 0.990 MTPA) by installation of
Pre-Grinder (Roller Press / Vertical Roller Mill) with Existing Cement Ball Mill (No Increase in Clinker Production)
At Village Lumshnong, Tehsil Khliehriat, District East Jaintia Hills (Meghalaya) Pre- feasibility Report
Star Cement Ltd. 15
o Hospital
A small hospital with all basic facilities has been provided within the unit premises.
o Weighbridge
Electronic weighbridges are available in existing unit to take care of the incoming and
outgoing materials in the existing plant premises.
o Laboratory, administrative and engineering office
Existing lab, administrative and engineering office within the premises of administrative
block/ CCR building.
o Parking
Adequate parking space has been provided in the unit premises for the parking of vehicles.
(vi) Soil classification
Soil in the area is found to be clay loam in texture. Most common practices of cropping
pattern are Jhumming cultivation with 80 % of the population depending on agriculture
practised on 10 % of the land as the primary source of income.
(vii) Climatic data from secondary sources
The climate is tropical which varies from western to eastern part of the plateau. East Jaintia
Hills District has tropical climate characterized by high rainfall and humidity, generally warm
summer and moderately cold winter. The lower elevated areas experience fairly high
temperature for most part of the year having a mean maximum of 23 deg. C to 26deg. C and
a mean minimum of 12deg. C to 17deg. C. The mean summer temperature is 26deg. C and the
mean winter temperature is 9 deg. C. The mean annual rainfall varies from 4,000-6,000 mm
with most rainfall concentrated from May to September.
(viii) Social Infrastructure available
Telephone and medical facilities are available in the nearby towns. Adequate infrastructure
has been developed by Star Cement Ltd., at their existing premises which include Colony for
staff and workers, School with X standard affiliated to CBSE Board, Occupational Health
Centre etc. Almost all the villages in the buffer zone are electrified.
5.0 PLANNING BRIEF
(i) Planning Concept (type of industries, facilities, transportation etc.) Town and country
Planning/ Development authority classification.
Existing industry is cement industry. Transportation of raw material and final product is
being / will be done via existing road and rail network and cement concrete road has been
developed within the existing plant premises.
Proposed Modernization & Expansion of Cement Production Capacity (0.792 MTPA to 0.990 MTPA) by installation of
Pre-Grinder (Roller Press / Vertical Roller Mill) with Existing Cement Ball Mill (No Increase in Clinker Production)
At Village Lumshnong, Tehsil Khliehriat, District East Jaintia Hills (Meghalaya) Pre- feasibility Report
Star Cement Ltd. 16
(ii) Population Projection
Temporary influx of people will be there as the managerial and supervisory staff will
generally be outsider.
(iii) Land use planning (breakup along with green belt etc.)
Since, the proposed expansion will be done within existing plant premises, thus no
additional land will be required. Out of the total plant area; 11.9ha (approx. 33 %of the total
plant area) is covered under greenbelt/ plantation in order to reduce dust and noise
pollution levels and to increase aesthetic beauty of the area.
(iv) Assessment of infrastructure demand (Physical & Social)
Star Cement Ltd., (formerly Cement Manufacturing Company Ltd.) has assessed the
demand of infrastructure (Physical & Social) in nearby area of the plant site and
development activities are being undertaken under corporate social responsibilities
program for rural development initiatives for the upliftment of the nearby communities
from time to time.
(v) Amenities/Facilities
Star Cement Ltd., (formerly Cement Manufacturing Company Ltd.) has constructed
hospital, school, canteen and club etc. for the permanent and contract employees.
It is proposed to develop the amenities / facilities in nearby area of the plant site as per
requirement of local people of the nearby area under corporate social responsibilities
programme.
6.0 PROPOSED INFRASTRUCTURE
(i) Industrial Area (Processing Area)
Following infrastructure will be provided as following:
o Bags go down
Space will be provided in the packing plant area for the storage of bags.
o Parking
Adequate parking space will be provided in the plant premises for the parking of vehicles.
(ii) Residential Area (Non-processing area)
Direct and indirect employment is being/ will be generated due to this project. Some
skilled manpower may be required from outside the area while remaining unskilled/ semi-
skilled manpower will be sourced from the local villages. Residential facility will be
provided to manpower hired from outside area.
(iii) Green Belt
11.9 ha (approx. 33 % of total plant area) has already been developed under greenbelt /
plantation.
Proposed Modernization & Expansion of Cement Production Capacity (0.792 MTPA to 0.990 MTPA) by installation of
Pre-Grinder (Roller Press / Vertical Roller Mill) with Existing Cement Ball Mill (No Increase in Clinker Production)
At Village Lumshnong, Tehsil Khliehriat, District East Jaintia Hills (Meghalaya) Pre- feasibility Report
Star Cement Ltd. 17
(iv) Social Infrastructure
Proposed expansion project will result in growth of the surrounding areas by increased
direct and indirect employment opportunities in the region including ancillary development
and supporting infrastructure.
(v) Connectivity
The site is well connected to NH - 44 (approx. 0.5 km in South direction from the plant site).
Nearest city is Shillong (approx. 66 km in NW direction from the plant site). Nearest Railway
station is Bihara Railway Station (approx. 35 km aerial distance & 73 distance km by road in
SE direction from the plant site). Nearest Airport Silchar is approx. 66 km in SE direction
from the plant site.
(vi) Drinking Water
Existing drinking water requirement is 10 - 15 KLD and there is no additional water
requirement for the proposed expansion; thus, total drinking water requirement after
expansion will be 10 - 15 KLD.
(vii) Sewage Treatment System
Domestic wastewater (240 KLD) generated from colony is being / will be treated in existing
STP and treated water is being / will be utilized in greenbelt development / plantation.
(viii) Industrial Waste management
Water used for cooling is being / will be partially subjected to evaporation and partially
recycling and hence, no wastewater will be discharged from the plant premises.
(ix) Solid Waste Management
o Dust collected from various air pollution control equipment is being / will be recycled
back to the process.
o Sludge generated from STP is being / will be used as manure in greenbelt development/
plantation.
(x) Power requirement and source
Existing power requirement is 12.5 MW and additional 3.0 MW is required for proposed
expansion project. Total power requirement after proposed expansion project will be
15.5MW, which will be sourced from MPL (Meghalaya Power Limited).
7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN
(i) Policy to be adopted (Central/State) in respect of the project affected persons including
home oustees, land oustees and landless labourers (a brief outline to be given).
Proposed expansion will be done within the existing plant premises and no additional land is
required for the same; hence R & R is not applicable.
Proposed Modernization & Expansion of Cement Production Capacity (0.792 MTPA to 0.990 MTPA) by installation of
Pre-Grinder (Roller Press / Vertical Roller Mill) with Existing Cement Ball Mill (No Increase in Clinker Production)
At Village Lumshnong, Tehsil Khliehriat, District East Jaintia Hills (Meghalaya) Pre- feasibility Report
Star Cement Ltd. 18
8.0 PROJECT SCHEDULE AND COST ESTIMATES
(i) Likely date of start of construction and likely date of completion (time schedule for the
project to be given).
The project will start only after obtaining Environmental Clearance and other clearances
from statutory authority. Project will be completed in 06 months period after getting all the
regulatory approvals.
(ii) Estimated project cost along with analysis in term of economic viability of the project.
Total cost of the Project: Rs. 62 Crores
Cost for Environment Protection Measures:
� Capital Cost: Rs.2.0 Crores
� Recurring Cost/annum: 0.10 Crores / annum.
9.0 ANALYSIS OF PROPOSAL (final recommendations)
(i) Financial and social benefits with special emphasis on the benefit to the local people
including tribal population, if any, in the area.
Proposed expansion project will result in growth of the surrounding areas by increasing
direct and indirect employment opportunities in the region including ancillary development
and supporting infrastructure. Special emphasis on financial and social benefits is being/ will
be given to the local people including tribal population in the area.
Development of social amenities will be in the form of medical facilities, education to
underprivileged and creation of self-help groups.
Meghalaya state will get revenues in terms of taxes and local people will get direct &
indirect employment. Business opportunities for local community will be available like
transport of cement to market, maintenance & house-keeping contract work, supplying
goods, food to people etc. In addition, lots of CSR activities are being / will be carried out by
the company.
(ii) Environment Friendly Project: As can be seen for this project that no additional land is
required
Nor there is any major increase in water consumption. Moreover it will lead to increase in
consumption of fly ash. Further the increase in road transportation on account of expansion
is also marginal i.e. 150 tonnes/day which is only about 5% of the total finished goods of the
plant. There will be drastic reduction in specific power consumption and noise reduction. All
these make this project environment friendly project. Further the company has already
replaced around 1700 bulbs with LED lights and is willing to go for other environment
friendly measures if any recommended to it.