PRE-FEASIBILITY REPORT

(structure as per MoEF&CC OM no. J-11013/41/2006-IA.II(I) dated 30.12.2010)

FOR

EXPANSION OF CEMENT PLANT

(FROM 2600 TPD i.e. 0.858 MTPA to 4500 TPD i.e.
1.485 MTPA), CLINKER PLANT
(FROM 2600 TPD i.e. 0.858 MTPA to 4500 TPD i.e.
1.485 MTPA)
ALONG WITH 10 MW CPP & 9.5 MW WHRS

LAND AREA- 52.949 HA (EXISTING) TO 94.20 HA

(AFTER EXPANSION)

AT

VILLAGE: THANGSKAI, P.O: LUMSHNONG,

DIST: EAST JAINTIA HILLS, STATE: MEGHALAYA

MEGHALAYA CEMENTS LTD.

Village : Thangskai, P.O. Lumshnong
District: East Jaintia Hills, Meghalaya, Pin : 793210
Email : meghalaya@topcem.in

Issue 01, Rev 1, August, 2022

 Meghalaya Cements Ltd.

CONTENTS

Sl. No. Description Page No.

1.0 Executive summary .......................................................................................... 1

2.0 Introduction....................................................................................................... 2
2.1 Identification of project and project proponent .............................................. 2
2.2 Brief description of nature of the project ........................................................ 3
2.3 Need for the project and its importance to the country and or region ............ 3
2.4 Demand-supply gap ...................................................................................... 4
2.5 Export possibility/ domestic market ............................................................... 4
2.6 Employment Generation (Direct and Indirect) ............................................... 4
3.0 Project description ............................................................................................ 5
3.1 Type of project including interlinked and interdependent projects ................. 5
3.2 Location with Coordinates ............................................................................. 5
3.3 Details of Alternate Sites & Environmental Considerations ........................... 8
3.4 Size/ Magnitude of operation......................................................................... 9
3.5 Project description with process details ...................................................... 10
3.6 Raw material required along with estimated quantity, likely source,
marketing area of final product’s Mode of transport of raw material and
Finished product ......................................................................................... 15
3.7 Resource optimization/ recycling and reuse envisaged in the project ......... 15
3.8 Availability of water its source, energy / power requirement and source ..... 16
3.9 Quantity of wastes likely to be generated (liquid and solid) and scheme for
their management /disposal ........................................................................ 17
3.10 Schematic Representations of the Feasibility drawing which give information
of EIA purpose ............................................................................................ 18
4.0 Site analysis ................................................................................................... 19
4.1 Connectivity................................................................................................. 19
4.2 Land form, land use and land ownership .................................................... 20
4.3 Topography ................................................................................................. 20
4.4 Existing land use pattern ............................................................................. 20
4.5 Existing infrastructure.................................................................................. 20
4.6 Soil classification ......................................................................................... 20
4.7 Climatic data from secondary sources ........................................................ 20
4.8 Social infrastructure available ..................................................................... 21
4.9 Major Operational Industries in 10 Km Radius Area around the Project Site
Industries .................................................................................................... 21
5.0 Planning brief ................................................................................................. 23
5.1 Planning concept......................................................................................... 23
5.2 Population projection................................................................................... 23
5.3 Land use planning (break up along with green belt etc.) ............................. 23
5.4 Assessment of infrastructure demand (physical & social) ........................... 24
5.5 Amenities / facilities..................................................................................... 24

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya i
 Meghalaya Cements Ltd.

Sl. No. Description Page No.

6.0 Proposed infrastructure .................................................................................. 24

6.1 Industrial area (processing area)................................................................. 24
6.2 Residential area (non processing area) ...................................................... 26
6.3 Green belt ................................................................................................... 26
6.4 Social infrastructure .................................................................................... 26
6.5 Connectivity................................................................................................. 26
6.6 Drinking water management (source & supply of water) ............................. 26
6.7 Sewerage system & industrial waste management ..................................... 26
6.8 Solid waste management ............................................................................ 26
6.9 Power requirement & supply / source ......................................................... 26
6.10 Air Pollution Control Equipment ............................................................... 26
7.0 Rehabilitation and resettlement plan .............................................................. 26
8.0 Project schedule & cost estimates.................................................................. 27
8.1 Project Schedule ......................................................................................... 27
8.2 Cost of the Project....................................................................................... 27
9.0 Analysis of proposal (final recommendations) ................................................ 27

LIST OF TABLES

Table No. Particulars Page No.

Table 1: Direct and indirect employment ................................................................ 5

Table 2: Coordinates of Project Boundaries ........................................................... 5
Table 3: Distance and direction (within 15 km) of water bodies from project
boundary ................................................................................................... 8
Table 4: Main machinery in the plant (Existing & Proposed)................................. 11
Table 5: Material balance of clinker, cement and captive power plant of the
project ..................................................................................................... 14
Table 6: Raw material and their sources, distance and mode of transportation ... 15
Table 7: Water Consumption Details (KLD) .......................................................... 16
Table 8: Air Pollution Measures Details ................................................................ 18
Table 9: List of industries ...................................................................................... 21
Table 10: Plant area break up................................................................................. 23
Table 11: Existing and proposed infrastructure....................................................... 24
Table 12: Summary of Investment Cost Estimates ................................................. 27

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya ii
 Meghalaya Cements Ltd.

LIST OF FIGURES

Fig. No. Particulars Page No.

Fig. 1: Extreme coordinates of project site (Based on Google Earth) ................. 6

Fig. 2: Location map ........................................................................................... 7
Fig. 3: Flow sheet of manufacturing process .................................................... 13
Fig. 4: Plant Layout .......................................................................................... 19
Fig. 5: List of Industries in 10 km Radius around the Project Site .................... 22

LIST OF ABBREVIATIONS

TPD - Tonnes Per Day

MTPA - Million Tonnes Per Annum
PFR - Pre-feasibility Report
MW - Mega Watt
WHRS - Waste Heat Recovery System
KLD - Kilo Litre per Day
NOC - No Objection Certificate
MVA - Mega Volt-Amp
DG - Diesel Generator
NER - North Eastern Region
MOEF&CC - Ministry of Environment, Forest & Climate Change
ML - Mine Lease
CPP - Captive Power Plant
OPC - Ordinary Portland Cement
VRM - Vertical Rolling Mill
PPC - Portland Pozzolana Cement
ESP - Electrostatic Precipitator
CPCB - Central Pollution Control Board
NH - National Highway
IMD - Indian Meteorological Department
AMSL - Above Mean Sea Level

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya iii
 Meghalaya Cements Ltd.

1.0 EXECUTIVE SUMMARY

Project name Expansion of Cement & Clinkerisation Plant from 2600

TPD (0.858 million TPA) to 4500 TPD (1.485 million
TPA) with 10 MW CPP and 9.5 MW WHRS
Project proponent Meghalaya Cements Ltd.
Location Village Thangskai, P.O. Lumshnong, District East Jaintia
Hills, State Meghalaya
Latitude* 25°11'59.96"N to 25°12'39.67"N
Longitude* 92°22'24.73"E to 92°23'18.91"E
Total Area Existing - 52.949 ha
Proposed additional - 41.251 ha
Total - 94.20 ha
Status of Land Land status Existing as per Proposed Total after
EC dated Additional expansion
25.03.2009 &
amendments*
In possession 52.949 41.251 94.20
To be acquired 0 0 0
* amendments are dated 30.04.2019, 19.08.2019,
12.09.2019 and 30.09.2020
Product Cement, Clinker and Power
Rated capacity
Sl. Product Existing Additional Total
existing & Proposed No. (MTPA) proposed (MTPA)
(MTPA)
1. Clinker 0.858 0.627 1.485
2. Cement 0.858 0.627 1.485
Working days 330
Manpower
Present Additional Total after
expansion
Direct Employees 376 20 396
Indirect Employees 982 100 1082
Total Employees 1358 120 1478
Expected cost of the INR 136 crores
project expansion
Fresh Water Existing: 1719 KLD
requirement Additional: 770 KLD
Total: 2489 KLD
Source of water Chynryntong- Umparti River
Treated waste water 383 KLD
reuse
Water Permission From Department of Irrigation vide NOC No.
AID(J)223/2007-2008/ dated 24.03.2008 for 0.04
Cumecs (3456 KLD)

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 1
 Meghalaya Cements Ltd.

Power requirement Existing- 13 MW

Additional- 8 MW
Total- 21 MW
Power source  Existing
 State Electricity Board 17 MVA (~16 MW)
 Captive Power Plant - 10 MW (available, used
on need basis)
 Future - WHRS - 9.5 MW
 Back up/ start up - 8 X 1.5 MW DG
Implementation 12-18 months after getting all statutory clearances and
Schedule placement of order for plant & machinery
* as per google earth

The information in this PFR has been sourced from the “Pre-feasibility
report for Expansion of Cement Plant (From 2600 TPD to 4500 TPD) at
Village Thangskai, P.O. Lumshnong, Dist. East Jaintia Hills, State
Meghalaya for M/s Meghalaya Cement Ltd., Meghalaya prepared by GVS
Consulting Engineers, October 2021”.

2.0 INTRODUCTION

2.1 Identification of project and project proponent

Project Proponent- M/s Meghalaya Cement Limited (MCL) owns and

operates a cement production line of about 2600 TPD capacity clinker and
corresponding cement at Thangskai, Meghalaya. The construction of
Meghalaya Cement was started around 2004. In 2006, first clinker and
cement were produced. Initially the plant was designed to produce about
900 TPD of clinker and corresponding cement. To enhance the production
capacity, MCL initiated a capacity augmentation project in 2009 which was
completed in 2010. After capacity augmentation project the clinkerisation
capacity of the plant was increased from 900 TPD to about 2600 TPD.
Presently the plant is being operated at about 2600 TPD on continuous
basis.

M/s MCL has been promoted jointly by Sri. Kailash Lohia, Sri Mahendra
Agarwal, Sri Nishant Garodia and Sri Amit Agarwal.

Project: Meghalaya Cements Ltd. (MCL) has a large integrated cement

plant located in Meghalaya at Village Thangskai, District East Jaintia Hills
with a clinkerization capacity of 0.858 MTPA, cement capacity to 0.858
MTPA and a 10 MW Captive Power Plant.

Now, it is proposing to enhance the capacity of the clinker to 1.485 MTPA,

cement capacity to 1.485 MTPA and a 9.5 MW WHRS to ensure 100%
uninterrupted power availability for expansion phase.

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 2
 Meghalaya Cements Ltd.

2.2 Brief description of nature of the project

The nature of the project as per Schedule to EIA Notification, 2006 & its
amendments is Item no. 3(b) for cement plants. This is a Category A project
as the cement plant production is more than the category A threshold of 1.0
MTPA.

2.3 Need for the project and its importance to the country and or region

Importance in the country : India is the second largest cement producing

country after China having an installed capacity of approximately 545 million
tonnes. The industry accounts for over 8% of the global cement installed
capacity with Southern region comprising 35% followed by Northern 20%,
Eastern 18%, Western 14% and Central 13% of the total cement capacity.
The industry, contributing significantly over the years towards employment
generation, government exchequer and railways (by way of freight).

India’s domestic cement production was nearly 294.4 million tonnes (MT) in
FY21 and accounted for over 7% of the global installed capacity in FY21.
India’s cement production capacity stands at 545 MT. In FY2027, cement
demand is expected to reach 419.92 MT. India's cement production is
expected to increase at a CAGR of 5.65% between FY16-22, driven by
demands in roads, urban infrastructure and commercial real estate. The
consumption of cement in India is expected at a CAGR of 5.68% from FY16
to FY221. Of the total capacity, 98% lies with the private sector and the rest
with public sector. Because of the expanding demand of different sectors,
i.e., housing, commercial construction, and industrial construction, as per
IBEF, cement production capacity stood at 502 million tonnes per year
(MTPA). The cement industry is expected to reach 550-600 Million Tonnes
Per Annum (MTPA) by the year 2025.

Regional importance : The total demand of cement in North East Region

(NER) is estimated about 9.4 million tonnes during 2020- 2021 considering
a CAGR of 6.5%. Out of 9.4 million tonnes, if capacity utilization is taken as
70% for NER cement plants, NER will produce only 7.9 million tonnes of
cement and balance of 1.5 million tonnes of cement shall be imported from
other outside regions. Therefore, from calculations, it can be concluded that
there is a shortage of at least 1.5 million tonnes of cement in NER.

The development projects initiated by Government of India / NEC will

generate fresh demand for cement in the NER:

 Airports - 5 sanctioned, 8 in pipeline, Rs 5,000 crores investment is

expected during next 10 years. Guwahati & Agartala airports to be
upgraded for international operations.
 Railways - Indian Railways has lined up several projects worth at least
Rs. 40,000 crores to connect capital cities of five North Eastern states

1
Source- https://www.ibef.org/industry/cement-presentation?msclkid=42c50b40cf8c11ecbc0c3fd4b06b29e1, Cement Industry
Report, Feb, 2022 accessed on 02.06.2022

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 3
 Meghalaya Cements Ltd.

which 20 major railway projects, encompassing 13 new lines, two gauge

conversions and five doublings with a length of nearly 2,624 kilometres
and several engineering marvels such as India’s longest double decker
rail-cum-road bridge, one of the longest tunnels in the country and the
world’s tallest pillar-based rail bridge.
 Hydro Power - Largest Hydro power potential (63000 MW of Hydro) in
India is in NER with 98% still untapped which will result in ~14 million
tonnes of cement demand.
 Smart Cities – Fund of Rs 14,124 crore is approved for 464 projects in 8
Smart Cities in Northeast.
 68 twin towers coming up at Baasista – Guwahati under Joint Venture of
Assam and NBCC costing Rs 14,000 crores.
 National Institute of Technology (NIT) is being set up at Nagaland
costing Rs 1,000 crores.2
2.4 Demand-supply gap

Presently, there is shortage of cement about 1.5 million tonnes in the North-
Eastern region which is being supplied by the plants outside the region. The
shortage is expected to increase as more and more infrastructure projects
are implemented. Therefore, expanding a cement plant from 2600 TPD to
4500 TPD is a prudent step, considering the present cement market
situation in the NER4.

2.5 Export possibility/ domestic market

Cement produced in the state will be consumed domestically. The main

market for the North-Eastern regions will be in the following order:

 Assam
 Meghalaya
 and rest of the NER states (i.e. Mizoram, Manipur, Tripura, Nagaland
and Arunachal Pradesh)

Assam and Meghalaya are the major cement consuming states of NER.
West Bengal & Bihar also have great potential. Clinker can also be exported
to neighbouring countries viz Nepal & Bangladesh.

2.6 Employment Generation (Direct and Indirect)

Meghalaya Cements Limited (MCL) has an established team for plant

operation, with good experience of projects, only few additional manpower
is envisaged during the expansion phase of the Project. The company has
already direct/ indirect employees so there will be minimum enhancement in

2
Source- Pre-Feasibility Report for Brownfield Expansion of Meghalaya cement 982from 2600 TPD to 4500 TPD, Oct 2021
accessed on 2.06.2022

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 4
 Meghalaya Cements Ltd.

manpower for the expansion of the project. The table for total manpower is
shown in Table 1.

TABLE 1: DIRECT AND INDIRECT EMPLOYMENT

Present Additional Total after expansion
Direct Employees 376 20 396
Indirect Employees 982 100 1082
Total Employees 1358 120 1478

3.0 PROJECT DESCRIPTION

3.1 Type of project including interlinked and interdependent projects

Cement plant is dependent on limestone for clinker production. Therefore,

interlinked projects will be limestone mines. However, in this case, the plant
has been operational and also has operational mines linked with it,
therefore, the proposal has not been considered from the point of view of
“interlinked projects” as per the definition of MOEF&CC. In addition to the
existing limestone mines used to source limestone for the existing project,
additional limestone deposits have been identified (containing possible
reserves of 22.02 million tonnes) and Grant of PL & ML and other statuary
clearances for limestone deposit is under process. Meghalaya Cement
Limited (MCL) is in process of acquiring more mining areas and reserves to
meet the minimum for more than 20 –25 years. However, the expansion of
this plant will not be adversely affected during this process of limestone
acquisition.

3.2 Location with Coordinates

The project is located in Village Thangskai, P.O. Lumshnong, District East

Jaintia Hills, Meghalaya. The locality is also known as Umpeh. The location
map is given in Fig. 2. The latitude and longitude of the site based on
Google earth is given in Table 2 and the corresponding map is shown in
Fig. 1.

TABLE 2: COORDINATES OF PROJECT BOUNDARIES

Coordinate No. Latitude(N) Longitude(E)
NM (North most) 25°12'39.67"N 92°23'16.21"E
EM (East most) 25°12'7.75"N 92°23'18.91"E
SM (South most) 25°11'59.96"N 92°23'17.60"E
WM (West most) 25°12'4.06"N 92°22'24.73"E

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 5
 Meghalaya Cements Ltd.

FIG. 1: EXTREME COORDINATES OF PROJECT SITE (BASED ON GOOGLE EARTH)

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 6
 Meghalaya Cements Ltd.

FIG. 2: LOCATION MAP

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 7
 Meghalaya Cements Ltd.

3.3 Details of Alternate Sites & Environmental Considerations

There is no alternate site proposed as it is an expansion project. The

chosen proposed site is more suitable as the expansion will be carried out
in the existing premises only.

Environmental considerations: The nearest Wildlife Sanctuary is Narpuh

WL Sanctuary whose ESZ is at a distance of 5.6 km in SE. The project area
lies outside the notified eco-sensitive zone. There are several rivers present
within the study area of the project as listed in Table 3.

TABLE 3: DISTANCE AND DIRECTION (WITHIN 15 KM) OF WATER

BODIES FROM PROJECT BOUNDARY
Sl. Particulars Distance & Direction
No. (km)
1. Lukha River 6.9 SE
2. Um Lunar 3.6 E
3. Um Sngat 4.0 E
4. Apha Nadi 11.6 S
5. Non Gang 9.5 SSW
6. Wah Lariang 4.3 SSW
7. Seshympa River 5.4 W
8. Rashniang Nala 6.9 NNW
9. Sebi Nala 12.3 NE
10. Lynriang 10.8 NW
11. Um Laro 8.2 NNW
12. Laphirawi Nala 9.2 NNW
13. Wahlong Nala 9.6 N
14. Um Badoh Nala 0.3 S
15. Um Utha Nala 2.5 W
16. Thangpyrshaid Nala 1.6 N
17. Kukha Nala 0.9 NE
18. Sakha Nala 2.8 NNW
19. Dongtangle Nala 2.4 N
20. Wah Thaniang Nala 5.8 NNE
21. Um Laper Nala 7.1 NNE
22. Kairang Nala 7.8 NNE
23. Urle Nala 11.5 N
24. Rasli Nala 12.4 NNE
25. Wah Sakhain Nala 9.4 NE

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 8
 Meghalaya Cements Ltd.

Sl. Particulars Distance & Direction

No. (km)
26. Um Thlu Nala 6.7 NE
27. Rangsniang Nala 12.3 NE
28. UM The Nala 10.0 NE
29. Latynger Nala 9.4 NE
30. Um Sangad Nala 13.4 ENE
31. Saisidung Nala 11.7 E
32. Raphingdung Nala 11.9 E
33. Pongkolo Nala 12.2 ESE
34. Singlei River 12.6 SE
35. Khuaingoi Nala 13.7 SE
36. Um Kiyang Nala 14.2 SSE
37. Um Lahe Nala 7.4 SSE
38. Um Talang Nala 4.3 S
39. Um Satain Nala 7.9 SSW
40. Jam Chhara Nala 11.6 S
41. Kuliang Chhara Nala 12.4 S
42. Rumplung Nala 10.0 SW
43. Larung Nala 11.8 SW
44. Um Tharang Nala 10.1 SW
45. Sharai Nala 13.0 SW
46. Um Kan Nala 8.7 SW
47. Um Bluh Nala 13.7 NE

3.4 Size/ Magnitude of operation

The existing project has clinkerisation production capacity of 0.858 MTPA, a

cement production unit of 0.858 MTPA and a Captive Power Plant of 10
MW at village Thangskai, P.O. Lumshnong, District East Jaintia Hills,
Meghalaya.

In the proposed additional project, expansion shall be carried out by

installing additional 0.627 MTPA clinker manufacturing capacity, 0.627
MTPA cement manufacturing capacity and a 9.5 MW WHRS. The WHRS is
exempt from obtaining environmental clearance, hence, activities related to
it have been initiated as on date.

After expansion, the total clinkerisation production capacity will be 1.485

MTPA, cement production capacity will be 1.485 MTPA, 10 MW CPP and

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 9
 Meghalaya Cements Ltd.

9.5 MW WHRS at village Thangskai, P.O. Lumshnong, District East Jaintia

Hills, Meghalaya.

3.5 Project description with process details

The Manufacturing process for each individual production unit is described

below:

3.5.1 Design basis

An existing clinker manufacturing unit, clinker grinding unit and cement

making plant is already there in the project and for expansion additional
units shall be established. The characteristics of existing and proposed
expansion are given below:

Sl. Description Existing Proposed Unit Total

No. Plant
1 Clinker Plant 0.858 MTPA 0.627 MTPA 1.485 MTPA
2 Clinker to cement Average
factor
2.1 Blended Cement 0.65 0.65 0.65
(PPC/Composite)
2.2 OPC 0.93 0.93 0.93
3 Applicable cement
standards
3.1 Blended Cement IS: 1489 (Pt- same same
(PPC/Composite) I)-2015
3.2 OPC IS: 269-2015 same same
4 Specific Heat ~727.81 kcal/ ~727.81 kcal/ ~727.81 kcal/
Consumption kg clinker kg clinker kg clinker
5 Raw meal to 1.526 1.526 1.526
Clinker Factor

 Average Gross Calorific Value of Coal has been considered as around

6400 Kcal/ kg coal (On equilibrated moisture basis) as seen in QCI’s lab
report ABCD8408 dated 05.05.2022.

 The theoretical raw mix design considered for plant sizing is as follow:

Material % in Raw mix

Limestone 87-89%
Clay (Siliceous & Aluminous) 10-12%
Laterite 1-2%

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 10
 Meghalaya Cements Ltd.

 It is also proposed that the available alternative fuels such as single use
plastic, waste plastic, used flyash PP bags, wood, tyre chips, slate,
permissible municipal waste etc shall also be co-processed with Coal.
However, above theoretical raw mix design is based on the coal only, as
the raw mix always demands frequent variation with respect to varying
characterizes of alternative fuels.

3.5.2 Main Machinery

The main machinery of the cement plant (existing and proposed) are as
follows:

TABLE 4: MAIN MACHINERY IN THE PLANT (EXISTING & PROPOSED)

Stage Material/ Machine Existing Proposed /
process capacity modified additional
capacity
Crushing Limestone Primary Crusher 350 t/h -
Process (Single Rotor Impact
Crusher)
Limestone Secondary Crusher 250 t/h -
(Reversible Impact
Hammer Crusher)
Limestone Tertiary Crusher - 300 t/h
Stacking and Limestone Stacker 600 t/h -
Reclaiming Reclaimer 400 t/h
Coal Stacker 100 t/h -
Reclaimer 100 t/h
Hoppers/ Lime Stone After Crushing 2 x 30000 t No
Silo Iron Ore Steel Hopper 150 t -
Sand stone NA NA
High grade L.S. Bunker 1 X 4000 t -
limestone
Raw Coal - 1 no. X 60 t -
RM Silo - 1 no. X 7500 t -
Clinker Silo - 1 no. X 26,000 t -
1 no.X 10000 t
Clinker Off- - - -
spec
Clinker - 300 t -
Gypsum - 100 t -
Fly Ash - 140 t -
Grinding Raw Mill Ball mill 2 X 100 t/h 330 t/h (total)
Coal Mill Ball mill Closed Circuit Vertical Roller Mill
Ball mill 35-40 t/h
2 X 12 t/h
Cement Mill Ball Mill 135 – 150 t/h
Upgradation of old
ball mill / Addition of
new VRM 100 TPH
Pyro Preheating Suspension Preheater 2 String of 4 Existing 2 Strings to
Processing stage suspension be separated for 2
preheater and separate lines with
calciner calciner.

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 11
 Meghalaya Cements Ltd.

Stage Material/ Machine Existing Proposed /

process capacity modified additional
capacity
Clinker Pier supported kiln 2600 t/day 4500 tpd (Total)
manufacturing
Clinker cooling Grate cooler 2600 t/day 4500 tpd (Total)
Clinker From cooler to Deep pan conveyors 220 t/h 220 t/h (New)
transport clinker silo
Packing and Cement Spout Rotary 2 X 120 t/h 3 X 120 t/h (Total)
Dispatch Electronic Packer
Cement Truck loaders 4 X 120 t/h 6 X 120 t/h (Total)

3.5.3 Manufacturing process of clinker and cement

(Source : Technical EIA Guidance Manual For Cement Industry, by IL&FS Ecosmart
Ltd., Hyderabad, September 2009)

Cement manufacturing process involves mining, crushing, grinding of raw

materials (principally limestone and clay), blending of raw meal, calcining
the materials in a rotary kiln, cooling the resulting clinker, mixing the clinker
with gypsum, and milling, storing, and bagging the finished cement.

The raw materials used to make cement may be divided into four basic
components: lime (calcareous), silica (siliceous), alumina (argillaceous),
and iron (ferriferous). The basic chemistry of the cement manufacturing
process begins with the decomposition of clay minerals into SiO2 and Al2O3
on the one hand and, of calcium carbonate (CaCO3) at about 900°C to
leave calcium oxide (CaO, lime) and liberate CO2.

The latter process is known as calcination. This is followed by the clinkering

process, in which the CaO reacts at high temperature (typically 1450°C)
with silica, alumina, and ferrous oxide to form the silicates, aluminates, and
ferrites of calcium. The resultant clinker is then ground together with
gypsum and other additives to produce cement.

The proposed plant will follow the dry manufacturing process, wherein the
raw materials will be ground and dried to raw meal in the form of a flowable
powder. The dry raw meal will be fed to the pre-heater or precalciner kiln or,
more rarely, to a long dry kiln.

In the dry process, the moisture content of the feed material can be up to
8% in case of ball mill or roller press and up to 15 % in case of grinding
operation with vertical roller mills (VRM). The dried materials will then be
pulverized into a powder and fed directly into a rotary kiln. The kiln will a
long, nearly horizontal (slope < 3 – 4 %), steel cylinder with a refractory
brick lining. The kiln will rotate about the longitudinal axis.

The pulverized raw materials will be fed into the upper end and travel slowly
to the lower end. The kilns will be fired from the lower end so that hot gases
pass upward and through the raw material. Drying, decarbonation, and
calcining are accomplished as the material travels through the heated kiln,
finally burning to incipient fusion and forming the clinker. The clinker will be

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 12
 Meghalaya Cements Ltd.

cooled, mixed with gypsum, performance enhancers or ash by weight and

ground to the final product fineness and particle size distribution. Thus,
OPC and PPC cements shall be made.

The manufacturing process is shown below:

FIG. 3: FLOW SHEET OF MANUFACTURING PROCESS

3.5.4 Captive Power Plant

Meghalaya Cement Ltd. has an existing captive power plant of 10 MW.

3.5.4.1 WHRS power generation unit

The existing plant has electrical energy from State Electricity Board,
Captive Power Plant and WHRS.

Waste heat from exhaust gases of preheater and grate cooler can be
effectively utilized for power generation. Considering 1.485 MTPA clinker
capacity and 5 stage preheater and modern grate cooler, WHRS potential
works out to 9.5 MW. Preheater exit gases after Waste heat recovery boiler
outlet shall be utilized for material drying in coal mill (VRM) and raw mill
(VRM). Cooler mid-air tapping for AQC boiler has been considered to
calculate WHRS potential from cooler side. Cooler vent air may be utilized
for material drying in cement mill (VRM) with slightly reduction in power
generation of WHRS.

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 13
 Meghalaya Cements Ltd.

3.5.5 Material Balance

The material balance of the entire plant (existing and proposed) is given in
Table 5.

TABLE 5: MATERIAL BALANCE OF CLINKER, CEMENT AND CAPTIVE

POWER PLANT OF THE PROJECT
Existing Additional Total
Raw Material Inputs Specific Quantity Quantity Specific Quantity
consump- (TPA) (TPA) consump- (TPA)
tion T/T tion T/T
Clinker Unit
Input Limestone 1.35 1158300 846450 1.35 2004750
Clay (Siliceous & 0.17 145860 106590 0.17 252450
Aluminous)
Laterite 0.01 8580 6270 0.01 14850
Coal & other fuels 0.17 148262 108345 0.17 256607
Sub-Total Inputs 1.703 1461002 1067655 1.70 2528657
Output Clinker 1.0 858000 627000 1.0 1485000
Losses 0.7 603002 440655 0.7 1043657
Sub Total Outputs 1.7 1461002 1067655 1.7 2528657
Cement Unit
PPC – input Clinker 0.65 557700 407550 0.65 965250
Fly ash 0.33 283140 206910 0.33 490050
Gypsum 0.02 17160 12540 0.02 29700
PPC-Output Sub Total PPC 1 858000 627000 1 1485000
OPC- input Clinker 0.93 797940 583110 0.93 1381050
Gypsum 0.02 17160 12540 0.02 29700
Performance 0.05 42900 31350 0.05 74250
Improver

OPC- Sub Total OPC 1 858000 627000 1 1485000

Output
OPC & PPC Total Cement at any 1 858000 627000 1 1485000
Output time (OPC & PPC)

Power plant
Input Coal 1 70000 0 1 70000
Output Fly ash 0.28 19800 0 0.28 19800
Losses 0.72 50200 0 0.72 50200
Sub-Total output 1.00 70000 0 1.00 70000

Air Pollution Control equipment dust are 100% recycled in clinker as well as
cement plant.

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 14
 Meghalaya Cements Ltd.

3.6 Raw material required along with estimated quantity, likely source,
marketing area of final product’s Mode of transport of raw material and
Finished product

The raw material requirement for the project (existing and additional) and
their sources are given below:

TABLE 6: RAW MATERIAL AND THEIR SOURCES, DISTANCE AND

MODE OF TRANSPORTATION
Sl. Raw material Quantity required per annum Source Distance Mode of
No. Existing Additional Total (in Km) utilization
(TPA) (TPA) (TPA)
1 Limestone 1158300 846450 2,004,750 Captive Mines 2/3 km By trucks
2 Clay (Siliceous & 145860 106590 252450 Brichyrnot ~15 Km-18 By trucks
Aluminous) (Meghalaya) km
3 Laterite 8580 6270 14850 Barak Valley ~85 Km By trucks
Area, Assam
4 1) Coal / Pet coke 218,262 108,345 326,607 Coal India Limited ~1100 - By Rail/
and its 2100 Km Trucks
subsidiaries. Spot
Auction/ Linkage
Auction /MSTC
etc./ Imported
2) Alternate Fuel (Plastic From Guwahati/ 10 km- By trucks
waste, PP bags, wood, Shillong 220 km
tyre chips, slate, /Jowai/Local areas
Municipal waste, etc.)
5 Clinker 858,000 627,000 1,485,000 Inhouse

6 Fly ash 283,140 206,910 490,050 West Bengal 600 to By Rail/

Power 1000 Km Trucks
Development /
NTPC Kahalgaon/
Own CPP
7 Mineral Gypsum / 17160 12540 29700 State mining Co. 450 Km By Trucks
Chemical gypsum / Ltd, Bhutan
Phoshpho gypsum / PP
Mold / etc.
8 Performance Improver 42900 31350 74250 East Jaintia Hills 15-20 m By Trucks
Total 3590202 2572455 6162657

3.7 Resource optimization/ recycling and reuse envisaged in the project

 Bag filters was already considered for the kiln, raw mill, cement mills
and ESP/ Bag house for clinker cooler in the existing plant. These
equipment shall be upgraded to meet the required pollution control
norms. The dust collected from these air pollution control equipment
(dust collectors, bag filters) will be recycled back into the process.
Additional bag filters shall be installed for expansion, where required.
 Neutralisation tank and sewage treatment system shall be used to treat
the waste water etc. for further reutilisation/recycle to achieve zero
liquid discharge.
PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 15
 Meghalaya Cements Ltd.

 No solid waste will be generated from the cement plant for disposal.
Solid waste generated within the plant shall be reused within the plant
itself.
 The ash generated from the captive power plant will be utilized in
cement making.

3.8 Availability of water its source, energy / power requirement and source

3.8.1 Water requirement

The requirement of fresh water for industrial activities and domestic activity
would be 2489 KLD. The water requirements will be met from the source of
Chynryntong- Umparti River for which a permission was taken from the
Department of Irrigation vide NOC No. AID(J)223/2007-2008/ dated
24.03.2008 for 0.04 cumecs (3456 KLD). Treated waste water (383 KLD)
shall be reused for green belt watering and sprinkling on road and parking.
Total fresh water and treated water use will be 2872 KLD.

TABLE 7: WATER CONSUMPTION DETAILS (KLD)

Unit Existing as per Revised Additional Total Waste water
EIA dated 2009 Existing generated
Cement Plant 1292.9 482 200 682 10
CPP & WHRS 3360 821 570 1391 40
Domestic 210 416 0 416 332.8
Misc. 6.7 0 0 0 0
Total 4869.6 1719 770 2489 382.8

It can be seen that the fresh water requirement mentioned in the

environmental clearance was 4869.6 KLD and the break up of which had
been given in the EIA report of 2009. However, in actual, the fresh water
consumption has been reduced and is currently 1719 KLD. The waste water
generated shall be reused as follows:

Land use Area Unit Rate of Total reutilisation,

consumption, KLD KLD
Green belt 31.086 ha 9.34 290.34
Road 7.336 ha 9 66.02
Parking 5.6 ha 4.7 26.32
Total 382.68

Water Distribution

Raw water will be stored in water tank for production purpose. Water
recirculation pump will pump water to cooling systems and other

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 16
 Meghalaya Cements Ltd.

equipments along production line such as raw mill, coal mill, cement mills,
preheater tower, clinker cooler, additive crusher, limestone & clay crushing
station.

Cooling water for raw mill, kiln, coal mill, cement mill shall be returned to the
tank for oil and grease separation before pumping to hot water tank. From
the hot water tank it will be cooled down by pumping to cooling tower and
supplied to cold-water tank.

Potable water supply

After-treatment potable water shall be in accordance with specified standard

and supplied to water tank and it will be pumped into the potable water
system in the whole plant.

Water supply for fire fighting

Water for firefighting will be stored in tank and will be pumped into water
supply system in case of fire. For the fire fighting, 3 nos. pumps shall be
provided i.e. 1st diesel operating, 2nd electrical pump and 3rd shall be Jockey
pump. Water supply system for firefighting outside buildings will be provided
with fire hydrants located at proper locations along roads within the plant.

3.8.2 Power Requirement

The power demand for the existing plant is estimated at 13 MW and after an
expansion it will be 21 MW. Power sources available are as follows:

 State Electricity Board: 13 MW (existing permission is 17 MVA ~16 MW)

 WHRS: 9.5 MW (proposed)

 Existing Captive Power Plant of 10 MW rated capacity (existing)

 Existing 8 X 1.5 MW DG for cold start of CPP/ backup

The consumption from the 10 MW CPP and shortfall from MPDCL shall be
met as feasible, depending upon cost of fuel and power rates.

3.9 Quantity of wastes likely to be generated (liquid and solid) and scheme
for their management /disposal

Air pollution

Existing plant design had been done with due care of environment and and
additional air pollution control systems shall be installed in expansion
phase.

The summary of the air pollution control systems are given below:

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 17
 Meghalaya Cements Ltd.

TABLE 8: AIR POLLUTION MEASURES DETAILS

Sl. Stack attached to Existing APC Proposed Total APC
No. measures* APC measures
measures
1 Primary Crusher Bag filter - Bagfilter
2 Secondary Crusher Bag filter - Bagfilter
3 Tertiary Crusher - Bagfilter Bagfilter
4 Coal Mill Bag filter Bagfilter Bagfilter
5 Cement Mill Bag filter Bagfilter Bagfilter
6 Clinker Cooler ESP ESP ESP
7 RABH (kiln and raw mill) Bag filter Bagfilter Bagfilter
8 Packing Plant Bag filter Bagfilter Bagfilter
9 Power Plant ESP - ESP

The material collected in the air pollution control systems shall be

recirculated back into the process and no disposal shall be there.

Industrial waste water

There will be minor waste water generation from the cement plant as the
plant uses dry manufacturing process and shall be reused as discussed in
section 3.8.1 earlier.

Domestic waste water

At all department offices, CCR, workshop, administrative offices like office

buildings, canteen, clinic etc there will be separate toilets. Waste water from
these areas will be treated by septic tanks in a decentralized manner. There
is a colony also within the project area which will have an STP.

Solid and Hazardous Waste Generation

 No solid waste will be generated from the cement manufacturing

process.

 Dust collected from various air pollution control equipment will be

recycled completely in process.

 Septic tank Sludge and STP sludge will be utilized as manure for green
belt development within the plant premises.

 Used oil (Hazardous Waste) will be sold to CPCB authorised recyclers.

3.10 Schematic Representations of the Feasibility drawing which give

information of EIA purpose

Process flow sheet has been given in Fig. 3 earlier describing the
processes. The layout plant is given in Fig. 4.

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 18
 Meghalaya Cements Ltd.

FIG. 4: PLANT LAYOUT

4.0 SITE ANALYSIS

4.1 Connectivity

The site is well connected to NH-6 which is approximately 0.15 km in west

direction from the plant site. Nearest city and airport is Shillong,
approximately 67 km aerially and 118 km by road in north west direction
from the plant site.
Nearest Railway station is Karimganj Railway Station at 37.5 km aerial
distance in south direction from the plant site. It is 106 km by road.

The site has telecommunication facilities like telephone, fax and wi-fi.

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 19
 Meghalaya Cements Ltd.

4.2 Land form, land use and land ownership

Total area required for the project is 94.20 ha. It is already under the
possession of Meghalaya Cements Limited. The land use of the entire plant
comprises of plant buildings, shed area, colony area, residential area,
storage areas, roads and green belt.

4.3 Topography

The topography is undulating and will be levelled in the areas where plant
construction and its activities have to be undertaken. It shall be attempted
that soil cutting and filling is balanced. The elevation of the plant area varies
from 809 m amsl (in north) and 774 m amsl (in central) portion based on
Google Earth.

4.4 Existing land use pattern

Existing project area is 52.949 ha, additional required for expansion is

41.251 ha. Total project area is 94.20 Ha, which is already under the
possession of Meghalaya Cement Ltd. The existing land is under industrial
use. The proposed land will also come under industrial use. Land cover will
change from open or vegetated to buildings, roads, storage yards, etc.

4.5 Existing infrastructure

MCL has already been operating facility for cement manufacturing at village
Thangskai, District Jaintia Hills of Meghalaya State. Hence infrastructure to
support the operation of the plant has been developed already. The same
shall be augmented to meet the expansion requirements in addition to new
construction in expansion area. The plant is having well established
residential colony to provide accommodation for plant personnel like Senior
management and essential services related personnel in the colony. Power
supply is available in the vicinity and same shall be sourced by the plant.

4.6 Soil classification

The soil in the study area is mostly deep brown, black soil, red soil, alluvial
soil, sandy soil and acidic soil. The acidic character is due to leaching of
bases caused by high rainfall. The sandstone in the area gave rise to sandy
and permeable texture soils.3

4.7 Climatic data from secondary sources

Temperature

As per the nearest IMD station, Shillong (1981 – 2010), the mean of the
mean of minimum temperature ranges from 5.9 °C in January to 17.9 °C in

3
Source- CGWR - Aquifer Mapping And Management Of Ground Water Resources, East Jaintia Hills District, Meghalaya-
accessed on 08.06.2022

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 20
 Meghalaya Cements Ltd.

July and the mean maximum temperature ranges from 14.9°C in January to
24.1 °C in August.

Rainfall

The total average rainfall from 1981 to 2010 is 2250.4 mm monthly variation
is from 12.8 mm in December to 496.5 mm in July.

Relative Humidity

The relative humidity is lower in the morning hours averaging 70%

compared to night hours scoring 84% of average. The relative humidity
varies from 54% in March to 86% in July during morning and from 68% in
March to 90% in September and October during evening.

4.8 Social infrastructure available

The plant is having well established residential colony to provide

accommodation for plant personnel and essential services related
personnel in the colony. The colony is having other facilities like Primary
health center, Community Hall, Recreation center & Shops Guesthouse,
School etc. A small shopping centre is also there to meet the daily needs.
Schools, Colleges, Hospitals and medical treatment facilities are also
available at Khlierhat which is about 16.3 km aerially & 23 km by road from
the plant site.

4.9 Major Operational Industries in 10 Km Radius Area around the Project

Site Industries

The list of industries operating in 10 km radius area around the project site
is given below:

TABLE 9: LIST OF INDUSTRIES

Sl. No. List of Industries Distance in km
1. Cement Manufacturing Company Limited. 2.0
(CMCL)
2. JUD Cement Limited. 1.2
3. Dalmia Bharat Cement Limited. 1.3
4. Goldstone Cements Limited. 2.0
5. Hills Cement Company Limited. 1.2
6. Amrit Cement Company Limited. 2.8
7. Max Cement Limited (Green valley) 4.9

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 21
 Meghalaya Cements Ltd.

FIG. 5: LIST OF INDUSTRIES IN 10 KM RADIUS AROUND THE PROJECT SITE

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 22
 Meghalaya Cements Ltd.

5.0 Planning brief

5.1 Planning concept

The Expansion activity is a clinker and cement plant. It is a red category

industry from the point of view of obtaining consents under the Air Act &
Water Act. Facilities required for the expansion project will be provided as
per requirements calculated in PFR of GVS Consulting Engineers LLP.
Transportation of raw material and final product will be done via road and
rail network.

5.2 Population projection

MCL already have sufficient staff for plant operation of the existing facilities.
As the project envisages, only certain addition is in existing working areas is
envisaged as follows:

Present Additional Total after expansion

Direct Employees 376 20 396
Indirect Employees 982 100 1082
Total Employees 1358 120 1478

Some of the new employees may be from outside and will be provided
accommodation in the existing colony of the company. Additional
construction will be undertaken for any additional employees desirous of
staying in the colony.

5.3 Land use planning (break up along with green belt etc.)

The existing and proposed additional land use of the area is given in Table
10.

TABLE 10: PLANT AREA BREAK UP

Sl. Particulars Area (hectare) Percentage
No. Existing* Additional Total (%)
1 Plant Area 14.401 0.988 15.389 16.34
2 Captive Power Plant area 4.358 0 4.358 4.63
3 Shed Area 4.195 0.288 4.483 4.76
4 Colony Area 2.667 0.278 2.945 3.13
5 A B C D Residential Area 1.938 0.249 2.187 2.32
6 Road area 4.956 2.38 7.336 7.79
7 Truck Parking 0 5.618 5.618 5.96
8 Greenbelt / Plantation 17.48 13.606 31.086 33.00
9 Others (maintenance area, 2.954 17.844 20.798 22.08
drain, play ground, park, etc.)
Total 52.949 41.251 94.2 100
*Source: M/s Meghalaya Cement Ltd.

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 23
 Meghalaya Cements Ltd.

5.4 Assessment of infrastructure demand (physical & social)

Meghalaya Cement Ltd. will assess the demand of infrastructure (Physical

& Social) in nearby areas of the plant site during the preparation of the EIA
through village level surveys. Accordingly, development activities will be
undertaken under corporate social responsibilities (CSR) program for the
upliftment of the nearby communities.

5.5 Amenities / facilities

Meghalaya Cement Ltd. have the necessary amenities and facilities for the
use of its employees such as dispensary, canteen, washrooms, rest sheds,
etc. The residential area will be marginally enhanced to accommodate any
additional staff and their families from outside the local area.

6.0 PROPOSED INFRASTRUCTURE

6.1 Industrial area (processing area)

The water and power related infrastructure proposed is already discussed in

section 3.8 earlier. Following infrastructure (Table 11) will also be provided
as following:

TABLE 11: EXISTING AND PROPOSED INFRASTRUCTURE

Infrastructure Existing Additional
Compressed Air 4 no. X 19.3 m3/min= 77.2 1 no. X 19.3 m3/min= 19.3
System m3/min m3/min
5 no. X 9.77 m3/min= 48.85
m3/min
Parking Area Not well defined 56180 sq.m.
Weigh bridges 1 X 80 t No
4 X 60 t
Air Condition & 108 t 20 t
Ventilation
system
General Store It is already existing. Existing General store is
enough to cater spare
management of additional
proposed project.
Workshop It is already existing. No expansion in
workshop is envisaged.
Administrative Administrative office is located Existing office shall be
office within the plant premises. continued for the
additional proposed
project.
Dispatch Office Dispatch office is located within Existing Dispatch office
plant premises. shall be utilized to cater
operation of existing and
enhanced capacities.

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 24
 Meghalaya Cements Ltd.

Infrastructure Existing Additional

Empty bag Store It is already existing Existing bag store is
enough to cater spare
management of additional
proposed project.
Time & Security Time office and Security office Existing Time office and
Office is located within the plant Security office is planned
boundary. to utilize for expansion
project
Canteen It is already existing Existing Canteen is
planned to utilize for
expansion project
Clinic OH&S centre is located inside Existing OH&S centre and
plant facility and hospital is hospital will be sufficient
located within the project to cater for the expansion.
boundary.
Control, Centralized Control Room for Existing Control Room
Instrumentation complete operation system. shall be utilized for
and Automation operation of new and
system existing plant from single
location. Additional E&I
requirement will be
considered in expansion
project.
Rest Room Existing plant has rest room Additional rest room
facility located in various areas facility will be provided as
for plant operation people. per the requirement within
the plant premises.
Pollution Control, Refer sec 3.7,3.8 and 3.9 Refer sec 3.7,3.8 and 3.9
Waste Water and
Solid Waste
Management
System
Storage Facilities
Limestone 2 x 30000 t Covered stockpile No
Correctives
Additives 1 x 30000 t Covered shed No

Coal 2 x 3000 t Stacker stock pile No

1 x 6000 t Covered shed
Fly Ash 1 x 14000 t Covered shed No
Clinker 1 x 10000 t Clinker stock pile 1 X 30000 t RCC Silo
1 x 26000 RCC Silo (future provision only)
1 x 16500 covered rectangular
storage
Cement OPC: 5000 T PPC: 5000 t
PPC: 5000 T PPC additional silo: 500 t
OPC/ PPC: 2000 T

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 25
 Meghalaya Cements Ltd.

6.2 Residential area (non processing area)

The plant already has an existing residential area inside the project
boundary. After generating direct and indirect employment due to this
project, the same residential area shall be used to accommodate the
additional manpower during expansion project. Minor construction will be
undertaken to accommodate any additional manpower desirous of staying
within the colony. The total built up area of the colony will remain below
20,000 sq.m.

6.3 Green belt

Out of the total plant area, 31.086 ha (approx. 33% of the total plant area)
will be covered under greenbelt/ plantation in order to reduce dust and noise
pollution levels and to increase aesthetic beauty of the area.

6.4 Social infrastructure

Expansion project will result in growth of the surrounding areas by

increasing employment opportunities in the region including ancillary
development and supporting infrastructure under CSR programs.

6.5 Connectivity

Refer section 4.1

6.6 Drinking water management (source & supply of water)

Refer section 3.8

6.7 Sewerage system & industrial waste management

Refer section 3.9

6.8 Solid waste management

Refer section 3.9

6.9 Power requirement & supply / source

Refer section 3.8

6.10 Air Pollution Control Equipment

Refer Additional Document no 5 of Form 1

7.0 REHABILITATION AND RESETTLEMENT PLAN

No rehabilitation and resettlement plan has been made as no displacement

of population is there. Total 94.20 ha land is already in possession with the
cement plant.

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 26
 Meghalaya Cements Ltd.

8.0 PROJECT SCHEDULE & COST ESTIMATES

8.1 Project Schedule

It is estimated that 4 months time for completing the pre-project activities

like finalization of project concept, preparation of Tender Documents, etc
and further considering the location of the plant, the forward and backward
linkages related to the project and taking constraints and contingencies in
picture, the total project implementation schedule for this project is
considered as 16-18 months from “Zero date” i.e. the date of plant &
machinery order placement.

8.2 Cost of the Project

The total investment for the expansion project works out to approximately
INR 135.66 Crores. The estimated investment cost for the project is based
on the requirement of fixed and non fixed assets

The summary of investment cost estimate is shown in the Table 12 below.

TABLE 12: SUMMARY OF INVESTMENT COST ESTIMATES

Sl. No. Description Amount in INR
(Lakhs)
1 Land and Site Development 150
2 Civil Works and Structures 1709
3 Plant and Machinery 10415
4 Engineering & Know How 75
5 Miscellaneous Fixed Assets 719
6 Pre-Operative Expenses 185
7 Contingency 513
Total 135.66

9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

Meghalaya Cement Ltd. is expanding an integrated cement plant located in

Meghalaya at Village Thangskai, P.O. Lumshnong, District East Jaintia Hills
with clinkerization capacity from 0.858 MTPA (2600 TPD) to 1.485 MTPA
(4500 TPD), cement making capacity from 0.858 MTPA (2600 TPD) to
1.485 MTPA (total of PPC and OPC), 10 MW CPP and 9.5 MW WHRS.

376 person (Direct employment) are there for the existing cement plant and
20 additional manpower is required for the expansion project and indirect
employment shall be there in security, transportation, etc. Furthermore, as

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 27
 Meghalaya Cements Ltd.

part of CSR activities, development activities shall be carried out in the

villages, thereby improving their social and physical infrastructure.

Air pollution control equipment is given in detail in section 3.9. Entire dust
collected in the systems shall be recyclable. Cement plant will not have any
solid waste. The solid waste from the captive power plant shall be ash and
100% used for cement making. Thus, with the advancement in technology
and by adhering stringently to permissible limits of emission along with
regular monitoring, it is possible to operate the plant with minimal impact on
the environment.

PFR - Expansion from 2600 TPD to 4500 TPD Cement Plant, East Jaintia Hills, Meghalaya 28