1

2015
Online PDF Version

Special Features

Site Reports

18

2

12

Tokuyama Factory

Energy Consumed on a Per-Unit Basisat the Tokuyama Factory

13

Kashima Factory

18

Amount of Waste Matter and ByProducts Used to Produce Cement

14

Group Company Reports

18

Material and Thermal Recycling
Amounts in Cement Production

18

Energy Consumption

18

Emissions of CO2

19

Emissions of PRTR-DesignatedSubstances

19

Emissions of Hazardous Air Pollutants

19

Discharge of Industrial Effluent
and Levels of COD

19

Breakdown of Waste Treatment
Methods

19

Landfilled and Recycled Waste

4

Achieving Safety Worthy of a "First-Rate
Cement Plant"
Analysis and Evaluation Capabilities
Driving Development and Safety

Site Information

Practice of Environmental Management

16

Tokuyama Malaysia Sdn. Bhd.
Tokuyama Chemicals (Zhejiang) Co., Ltd.

6

Performance in Fiscal 20147

Environmental Accounting

7

Measures to Help Combat Global
Warming

Detailed Data

9

Reducing Atmospheric Emissions andWater Pollution

17

Environmental Data for Tokuyama

17		

Emissions of SOx, NOx, and Soot

17		

Discharge of Nitrogen and Phosphorous

17

Waste Management

10

Recycling and Reducing Waste

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Third-Party Review

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2● 1 Achieving Safety Worthy of a "First-Rate Cement Plant"● 2 Analysis and Evaluation Capabilities Driving Development and Safety

Special Feature 1: Achieving Safety Worthy of a "First-Rate Cement Plant"

Making One of Japan's Largest Cement
Plants Safer and Stronger
At the Tokuyama Factory's Nanyo Plant, three large kilns yield the highest single-plant production
capacity in Japan. Tokuyama rigorously implements environmental preservation and safetymeasures, and treats safety as an absolute prerequisite for all operations.

How Tokuyama Ensures Safety at Its Cement Plant

improvements. These tasks have now been implemented

A cement plant is a very hazardous workplace. Massive

Department, and are now being carried out on a continuingequipment operates at high voltage and extreme tempera-basis as voluntary management initiatives.

at the various workplaces under our Cement Manufacturing

tures, and numerous conveyor belts pose further risks. Moreover, a cement plant consumes huge quantities of mineral,
and wastes, as raw materials, which means fine-tuning ofoperations is required. Frequent stops and starts are handled
remotely in a central control room, so it is extremely important that each worker be very safety-conscious.

Problems and Accidents That Have Happened
Both in the Company and Elsewhere Used to Enhance
Safety Consciousness.
Discussions of accident case histories are among the vol-With this in mind, Tokuyama has undertaken many differ-untary management initiatives carried out at Tokuyama.

ent activities. These include: discussions based on accident

In these discussions, we focus on selected accidents thatcase histories to identify the causes of accidents, and prevent

have actually occurred to encourage employees think about

them; hands-on learning activities to provide experience withwhether the potential for the same sorts of accidents exists,

operation of actual machinery; and “5S model workplace*"and to devise measures to prevent them. Our goal is toactivities designed to show how problems and accidents canincrease everyone's safety consciousness.

be avoided by maintaining a clean and orderly workplace.
To ensure safety and quality, and to improve productivity, more than 30 years ago we set about a wide range of＊ The term “5S” refers to the 5S principles (a system in Japan for promoting
sorting, setting in order, systematic cleaning, standardizing, and sustaining
discipline).

The importance of safety-conscious
individuals and thorough information sharing
Kenji Tanaka

Manager, Manufacturing Section,
Cement Manufacturing Dept.
During periodic maintenance, morethan 400 workers and dozens of
items of heavy equipment enter thepremises, and ordinary operations
take place right alongside inspections and repairs. Hazards therefore
increase on such occasions. Safety
patrols, maintenance meetings, andother such activities carried out
together with contractors serve toshare information and ensure safety.
At everyday work locations, as well,information on near-miss accidents
is shared among all workers, andcorrective action is taken to eliminate latent hazards before theycause accidents.

Special Features

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Third-Party Review● 1 Achieving Safety Worthy of a "First-Rate Cement Plant"● 2 Analysis and Evaluation Capabilities Driving Development and Safety

Special Feature 1: Achieving Safety Worthy of a "First-Rate Cement Plant"

petition, and spurs stronger communication within andamong company divisions, which leads to greater trustand cohesion.

Going all out in the conduct of safety
activities

Last year, Tokuyama's Kiln No. 5 operated for 128 days ina row. It is no mean feat for the high-temperature, high-volt-

Information on accidents thathave occurred is publicly posted.

age equipment at a cement plant to operate continuously forso long, because the plant processes huge quantities of materials, including waste matter. It is Tokuyama's painstaking
Tokuyama’s Materials Office has been certified as a
“5S model workplace.”

dedication to safety that enabled this achievement.

Koji Uchiyama

Foreman, Cement Manufacturing Dept.
In our voluntary management initiatives, we are working to installsafety railings on our conveyor
belts. Some have commented
that the railings are “hard to inspect,” but we’re moving ahead,with the idea that we’ll go to any
length for the sake of safety.

Hands-on learning activity

Building a plant where people are educated so
nothing will daunt them

We organize hands-on learning activities using actual
equipment so that participants can experience the feel ofdealing with hypothetical hazards. The idea is to instill anawareness of the importance of safety activities.
Our "5S model workplace" activities focus on such things
as equipment storage locations and quantities. In addition
to ensuring safe passageways through the workplace,these activities also instill an awareness of the need tomaintain a clean workplace, which has the added benefit ofincreasing efficiency.

Safety Activities Provide a Forum for Active Communication,
and Generate Trust
Descriptions of voluntary management initiatives are publicly posted so that everyone can see the state of progress
at each company division. This generates a spirit of com-

Kazuhiro Yoshioka

Doctor of Engineering
General Manager,
Cement Manufacturing Dept.

Manufacturing cement involves a lot of complex
processes. If there’s a single person around who
isn’t highly safety conscious, it can lead to amajor accident. The “safety first” ethic is sharedthroughout the Manufacturing Department, andwe’ve taken it to such a height that, no matter
who you ask about something, you’re going to
get the same response. It’s important to conduct
daily operations on the basis of this ethic.
We have a great personnel training programin the Cement Manufacturing Department. Veterans provide instruction right on the production
floor. The trainees take notes, which they takeback to their desks to review. This basicallymeans that each employee, in addition to theCompany’s operations manual, has a completely
original set of teaching materials in his or her
possession.

I want to declare my determination to createa “first-rate cement plant.” What that means, ina word, is that “no matter happens, we’ll remain
undaunted.” It means that we’re self-sufficient, andcan act flexibly to make corrections and improvements in response to a changing environment. To
be able to do that, safety is an absolute necessity.
We broke the record last year for consecutive days in operation at a cement kiln. We
intend to see that all of our employees keep taking corrective actions and putting forth an effort
so that we can continue to operate safely andmaintain a zero accident record. Also, I’d liketo see Tokuyama train people so that they’re
prepared to work anywhere in the world. We’ve
begun shipping concrete overseas. If we cultivate people who can compete overseas, thenI do believe we will continue to be a “first-rate
cement plant.”

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Third-Party Review● 1 Achieving Safety Worthy of a "First-Rate Cement Plant"● 2 Analysis and Evaluation Capabilities Driving Development and Safety

Special Feature 2: Analysis and Evaluation Capabilities Driving Development and Safety

Advanced analytical Techniques Support
Development of Safe, Reliable Products
Globalization has triggered increasingly ﬁerce R&D competition, and chemical manufacturers are
expected to exercise Responsible Care. It is the RC Research Department’s cutting-edge analyses
and assessments that enable Tokuyama to address these needs so successfully.

Specialists inAnalysis and Evaluation, Environmental Analysis, and Risk Assessments

Commitment to Responsible Care

Q What is Tokuyama doing to ensure that its chemical

Q What is the organizational structure of the RC Research

products do not pose safety concerns?

Department ?

Production processes are expected to be safe, with as little

The RC Research Department has an Environmental Analysis

environmental impact as possible. The Company carries out

Team and an Analysis and Evaluation Team. The Environ-daily monitoring under the Tokuyama Factory’s safety man-mental Analysis Team analyzes and monitors the air pollut-

agement policy and environmental policy to be sure that pre-ants and effluent that are discharged by the Tokuyama Fac-

fectural and city discharge standards (which are even more

tory. This team plays an important environmental protection

stringent than national standards) are being met. In addition,role through its use of advanced environmental analysis andthe Company also monitors to ensure that the even-stricter

risk assessment techniques.

voluntary management standards of each manufacturing

Developing the trained eye of an analyst
Yoshiyuki Kitajima

General Manager, RC Research Dept.
As an analyst, you need two different
skill sets. You have to have expertise as
an analyst, and you also have to be able
to decide what is to be analyzed andhow to go about it. To develop theseskills to the highest level, you have to beable to think about how your analysis
will be put to use in the Company’s operations. I want to train people with thistype of ability.

The Analysis and Evaluation Team, which operates out ofdivision are being satisfied. Even when all standards are be-

the Tokuyama Factory and the Tsukuba Research Labora-

ing met, any unusually high reading will be reported to thetory, works together with outside organizations to support

Environmental Management Section and to the manufactur-development. One way it does this is by assessing the safety

ing division, which will check on the situation and take any

Whenever a reading is out of the ordinary, feedback is pro-of new compounds. In this and many other ways, this teamnecessary response measures.

vided immediately to the production site. Our goal is to im-

contributes to improved product safety and quality.

Q So even the tiniest anomalies at a production site are
discovered?

prove production processes and enhance quality. We stay inclose touch with production sites in order to nip problems inthe bud and continue operating stably.

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Third-Party Review● 1 Achieving Safety Worthy of a "First-Rate Cement Plant"● 2 Analysis and Evaluation Capabilities Driving Development and Safety

Special Feature 2: Analysis and Evaluation Capabilities Driving Development and Safety

Advanced Analytical Techniques Yield
Contributions to Tokuyama and Society

Contributing to Neighboring Residents’ Safety and Peace of
Mind

Counterproposals Lead to Breakthroughs

Q You’re expected to maintain the impartiality of a third

process?

Q So, I guess we could say that your objectives are theOne example of our support role would be the manufacturesame as those of R&D?

The Tokuyama Factory is located near a residential area. Toof bulk pharmaceuticals, which constitute the active ingre-

That’s exactly right. By further enhancing our analysis andgain the trust of neighboring residents, we measure the pres-dients in generic drugs. The first step in the R&D process isevaluation techniques, we make ourselves indispensable toence of harmful substances on the factory premises and into analyze the original drug and determine what the active

the R&D and manufacturing departments. And in doing so,

the air. Also, for substances requiring priority action—which

ingredients are. Once the active ingredients are known, you

we contribute to the company and to society.

may eventually subject to regulatory restrictions—we havecan decide how to approach the making of a generic ver-developed analytical techniques, and voluntarily measuresion, and set your objectives. Also, if you discover impurities

their presence.

during the course of development that could cause side

party, right?

Q What kind of support role do you play in the R&D

effects, you then have to determine the molecular structureand find a way to reduce impurities. The R&D department
also does analysis, but we are the ones who specialize in

A development partner that isuseful for its unique perspective

analysis and evaluation.

The Fine Chemicals Development Department at Tsukuba
Research Laboratory develops bulk pharmaceuticals forgeneric drugs. To make bulk

Q So analysis drives R&D?
As an in-house research department, the RC Research Depart-

ment is valuable to Tokuyama not just because it provides

The critical essence of analysis —questioning the fundamentals
Shota Honda

Research Chemist, RC Research Dept.
When someone comes to you needing analytical support, the key thing
you’ve got to do is to ask questions
about the fundamentals. If you knowwhat someone is really trying toachieve, you’ll just naturally see what
analytical techniques will be needed.
I want to develop my analytical skills,
one day at a time, one small job at atime.

the results of its analyses. In addition, our laboratory can also
take the findings from an analysis and put forward a counterproposal for a solution.
When we see value generated that is different from theresults of analysis done by the R&D department, we provide
feedback, including an explanation of how to interpret themeaning of the data. Having collaborated on an examinationof the data, together we can change the analysis conditions
and methods in order to arrive at a solution.

Hiroyuki Mori

Researcher, Fine Chemicals
Development Dept.

pharmaceuticals that perform even better than thoseused in the original drug, wehave to achieve a purity levelof one part per billion. When
working to explore syntheticroutes or reduce impurities,
analysis and evaluation are
indispensable at each stepof the development process.
Our Analysis and Evaluation
Team comes up with analytical methods that reflect a
totally different perspectivefrom ours in the Development Department. That’s
very helpful.

Practice of Environmental
Management

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Third-Party Review● Performance in Fiscal 2014
● Environmental Accounting● Measures to Help Combat Global Warming● Reducing Atmospheric Emissions and Water Pollution● Recycling and Reducing Waste

Practice of Environmental Management

For Tokuyama, the pursuit of proactive initiatives to protect theearth＇s environment is an important part of its corporate social
responsibilities. Accordingly, the Company practices environmental
management that takes into account the natural environment in all
business activities.

Flow of Materials in Business Activities

INPUT

OUTPUT
Production

Environmental Management at
Tokuyama

Waste andby-products

1,790

Fuel

1,820

Raw materials

5,900(44,400,000 gigajoules)

Performance in Fiscal 2014

Industrial waterTokuyama

Products

5,750

41,700Carbondioxide (CO2)

Waste(incinerated and landfill)

22

Substances withenvironmental impact

9.7

Process effluent≫ Flow of Materials in Business Activities

5,910

24,000

Coolant water and other types of eﬄuent

Tokuyama works to accurately determine the input and out-

(Unit: 1,000 metric tons)

put of materials for production, and regularly sets new targets

Note: All amounts are for Tokuyama Corporation on a

non-consolidated basis in fiscal 2014

aimed at reducing environmental impact.

≫ Results of Environmental Protection Initiatives in
Fiscal 2014
Among its targets for reducing environmental impact in fiscal

Results of Environmental Protection Initiatives by
the Tokuyama Factory in Fiscal 2014
Category

2014, Tokuyama met targets for soot emissions, water qual-

Items
Atmosphereity (chemical oxygen demand, nitrogen, and phosphorus),
PRTR-listed substances, recycling, and near-zero waste. The
Company also made progress in reducing per-unit energy

Environmental
Impact Reduction

Water Quality

consumption in fiscal 2020 by 3.0% compared to the fiscal
2005 level.
Regarding performance data for fiscal 2015 and beyond, Tokuyama has set a separate numerical management target for each department to maintain the current
low-impact situation.

Global Environment
Conservation
Waste Reduction

FY2014 Target

Symbols:

FY2014 Result

Soot

Emission target reset to 200 metric tons per year to reflect operating
forecasts and characteristics of facilities

-33%

COD

Same level as the fiscal 2010 result

-12%

N

Same level as the fiscal 2010 result

-19%

P

Same level as the average result for the previous three years-13%

Goal achieved,

RatingGoal not achieved

FY2015 Target

Maintain the current lowimpact situation

PRTR

PRTR

Same level as the average target values for the previous three years-27%

EnergyConservation

Energy consumption on a
per-unit basis

3% reduction of per-unit energy consumption by fiscal 2020
compared to fiscal 2005

-2.1%

Improve per-unit energy
consumption of products

Recycling

Effective utilization rate

Maintain at 94%

94.0%

Maintain at 94%

Zero emissions“Zero emissions” rate

Maintain at 99.9%

99.9%

Maintain at 99.9%

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Third-Party Review● Performance in Fiscal 2014
● Environmental Accounting● Measures to Help Combat Global Warming● Reducing Atmospheric Emissions and Water Pollution● Recycling and Reducing Waste

Practice of Environmental Management

total was generated by pollution control, 17% by resource recy-

Environmental Accounting

cling, and 7% by global environmental conservation.
In fiscal 2014, Tokuyama made principal environmental

Measures to Help Combat Global
Warming

Tokuyama has been carrying out environmental accounting

investments for upgrading equipment at electrostatic precipi-

Tokuyama participates in Keidanren’s Voluntary Action Plan on

since fiscal 2000 in order to accurately determine and analyze

tator and wastewater treatment facilities.

the Environment, as a member of one of the industries covered

the investment amounts and costs associated with its environ-by the Action Plan. It is via this Action Plan that Tokuyama ismental conservation activities, thereby providing a sound basis≫ Economic Benefits of Environmental Management

for making environmental investments.

Economic benefits are determined by calculating only mone-

Tokuyama is making steady progress in conserving energy

tary gains on the reduction of energy consumption, the sale ofthroughout its business activities, and supporting efforts byvaluable waste, the reduction in waste disposal costs throughemployees to save energy at home.

≫ Environmental Costs

working to achieve its 2020 emissions reduction target.

waste recycling, and the reduction in raw material and fuel60% was intended for resource recycling, followed by 21% forcosts through waste recycling. In fiscal 2014, these economic≫ Promoting Energy Conservation

pollution control, and 10% for management activities. Mean-

benefits totaled almost ¥1.46 billion, a slight decrease of ¥230

Tokuyama consumes a vast amount of energy to manufac-

while, among environmental costs in fiscal 2014, 69% of themillion compared to the previous fiscal year.

ture its core products such as caustic soda, cement, andEnvironmental Preservation Costs

Economic Benefits in Fiscal 2014

Unit Energy Consumption Index* (Tokuyama Factory)Category

Major Activities

Costs in Business Areas

Of Tokuyama’s total environmental investment in fiscal 2014,

AmountInvested(¥ million)

Costs(¥ million)

Pollution Control

Installation of electrostatic precipitators anddrainage conduits, replacement of tanks

163

4,526

GlobalEnvironmental
Conservation

Optimization of freezer equipment,
upgrade of refrigeration equipment for lowtemperature warehouses

66

493

Resource Recycling Upgrade of desalination equipment, PCB
waste treatment expenditures, etc.
Upstream andDownstream Costs
Management Activity
Costs

Installation of environmental analysis
equipment

Research andDevelopment Costs

463

1,117

0

1

81

250

0

0

Material Benefit(1,000 metric tons)

Category
Gains on Reduction in Energy Consumption-

190

Gains on Sale of Valuable Waste

72

170

251

649

251

453

-

1,462

Gains on Reduction in Waste Disposal Costs
through Waste Recycling
Gains on Reduction in Raw Material and FuelCosts through Waste Recycling
Total

Cumulative Total of Environmental Investment（Billions of yen）
400
353

Greenification and beautification measures
Production of CSR report

076

Costs for Environmental
DamageImposition, management of a former mining
site

0

111

200

774

6,575

100

100

100

100

99.4

99

97.9

98

97.0（Target）

96
358

370

379

387

95

300

0

Per-unit energy consumption（％）

97(Calculated from Fiscal 1990)

Social Activity Costs

Total

Economic Benefit(¥ million)

2005

12

13

14

20（FY）＊ The unit energy consumption index is calculated using a method recommended
by the Japan Chemical Industry Association (JCIA).

10

11

12

13

14

（FY）

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Third-Party Review● Performance in Fiscal 2014
● Environmental Accounting● Measures to Help Combat Global Warming● Reducing Atmospheric Emissions and Water Pollution● Recycling and Reducing Waste

Practice of Environmental Management

The objectives of the program are to raise awareness ofpolycrystalline silicon. It also emits carbon dioxide (CO2),

cooler, casual clothing in offices in the summer to reduce theone of the greenhouse gases, primarily in its burning of fossil

need for air conditioning.

global warming among Group employees, encourage them tohouseholds. The Company covers part of the costs incurred

The Company is working to reduce CO2 emissions by≫ Contributing to Efforts to Combat Global Warming in
the Consumer Sector

implementing energy conservation measures, including up-

The Tokuyama Group is working to help reduce household

friendly products closely connected to the Group’s business,

grading to more energy-efficient equipment. The Tokuyama

CO 2 emissions by providing its Shanon brand of plastic

namely residential-use plastic window sashes and solar

Factory, which accounts for more than 99% of the Company’s

window sashes, which are highly effective for saving energy

power generation systems. Tokuyama continued to offer the

total energy consumption, reduced per-unit energy consump-in residences.

program for the seventh year in fiscal 2014, a year when it

fuels and decarboxylation of limestone, which is used as araw material for cement production.

save energy, and help them reduce CO2 emissions from theirby employees for purchasing and installing environmentally

implemented measures to improve profitability. The usage oftion in fiscal 2014 by 2.1% compared to the fiscal 2005 level,

The Group is also making advances in the development

advancing the Company’s goal of reducing per-unit energyof other technologies that can help combat global warming,

consumption in fiscal 2020 by 3.0% compared to the fiscal

such as polycrystalline silicon for solar cells and electrolyte

2005 level.

membranes for fuel cells.

≫ Initiatives at Offices≫ Global Warming Prevention Support Program

In fiscal 2014, the Company’s Tokyo Head Office made en-

As part of its CSR-based environmental, energy-conservation

In addition, Tokuyama has set up a new groupware-based

ergy-saving settings to computers, removed some lights, andand social-contribution initiatives, Tokuyama launched its

portal site for the program. The site is regularly updated withstrictly regulated air conditioning. It also continued to participate

Global Warming Prevention Support Program for all Tokuyama

product usage reports and helpful information, such as rec-in the government-led Cool Biz campaign, which encourages

Group employees in April 2008.

ommended websites about global warming.

Energy Consumption

CO2 Emissions（Thousands of gigajoules/year）（1,000 metric tons/year）

60,0002,800

50,00040,00049,90037,600

2,600

2,800

44,20043,70030,0003,000

20,00020

1,930

sumption tax went up in Japan in April 2014.

1,420
4,510

Plastic Window Sashes

210
230

200
240
6,000

following the rush in demand in fiscal 2013 before the con-Adoption of Environmentally Friendly Products

2,800
44,400

1,550
4,730

3,290

200
230

190
210
1,570
4,020

1,680
4,020

200
230
1,630
4,050

10,00009010Tokuyama Corporation

11

12

Group companies

13

14 （FY）

0

90

In fiscal 2014, the number of subsidies for such productunits was lower than in fiscal 2013. This was due to the lag

9,000

2,800
52,500the program by employees is described below.

10

11

12

13

■ Attributable to fuel■ Attributable to raw materials■ Attributable to waste ■ Group companies

14

（FY）

Number of cases ofsubsidization

Solar Power Generation Systems
Number of casesof subsidization

Units

kW

FY2010

7

91

30

129

FY2011

13

174

22

87

FY2012

6

61

23

108

FY2013

8

113

34

180

FY2014

8

80

11

58

Total

61

837

134

620

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Third-Party Review● Performance in Fiscal 2014
● Environmental Accounting● Measures to Help Combat Global Warming● Reducing Atmospheric Emissions and Water Pollution● Recycling and Reducing Waste

Practice of Environmental Management

Reducing Atmospheric Emissions andWater Pollution

and Transfer Register (PRTR)* system. Every workplace handlingemitted from these facilities to ensure that amounts are below

these substances undertook measures to reduce emissions inregulatory limits.

fiscal 2014. As a result, the Company reduced its emissions to≫ Amounts of Industrial Effluent and Wastewater

27 metric tons compared to the previous fiscal year.

Tokuyama has been actively working to help protect the naturalenvironment from early on in its history, implementing a wide

The Tokuyama Factory follows a stringent system for monitor-＊ The PRTR system collects and publishes data on the sources of designatedharmful chemical substances and the amounts of these substances discharged in
the environment or transported from production sites as part of waste matter.

range of measures designed to reduce pollutants into the atmosphere and water systems.

ing industrial effluent and purifying wastewater using treatment
equipment in order to comply with regulatory standards andlimits set by the local government, as well as the Company’s≫ Amounts of Atmospheric Emissions≫ Amounts of Hazardous Air Pollutant Emissions

In order to reduce emissions of sulfur oxides (SOx), nitrogen

Tokuyama generates chloroethylene and three other sub-ploys activated sludge treatment facilities for reducing theoxides (NOx), and soot into the atmosphere, Tokuyama equips

stances that are among the 12 substances subject to volun-

discharge of nitrogen and phosphorous and meeting chemicalits boilers, cement kilns, and other facilities that generate thesetary controls in Japan’s Air Pollution Control Law. According-

oxygen demand (COD)* regulations for overall water quality.

substances with emission control systems, including flue gas

ly, the Company has formulated a voluntary action plan andPhosphorus emissions in 2014 were down from the year

desulfurizers, denitration equipment, low-NOx burners, andcarries out ongoing measures for reducing the emissions ofbefore, as was COD. Nitrogen emissions rose from 2013,high-performance dust collectors. In fiscal 2014, the Company

these substances.

however, due to an increase in the overall operating rate of

reduced emissions of NOx, SOx and soot compared to theown standards, which are even stricter. The factory also em-

related equipment.

previous fiscal year, as a result of lower operating rates at man-≫ Measures to Reduce Dioxins

ufacturing facilities.

Tokuyama’s waste oil incinerators and certain equipment in its
vinyl chloride monomer manufacturing facilities are subject toregulations under Japan’s Special Measures Law for Countermeasures against Dioxins. Accordingly, the Company measures

24 were subject to registration under the Pollutant Release

the concentrations of dioxins in exhaust gases and wastewater（metric tons）（metric tons）

15,00012,0009,000
6,000

10,000
275

148
2,890

3,000
0

8,000

90

SOx emissions

1,630
10

8,600

8,400

191

190

2,180

11

NOx emissions

174

1,450
12

9,200

8,850

135

750

550

13

14
（FY）

Soot emissions

Nitrogen and Phosphorus Emissions (metric tons)

PRTR Substance Emissions

Hazardous Air Pollutant Emissions（metric tons）（metric tons）
120
103

400

250

320

200

240

150

160

100

80

50

0

0

237

100

21

40
38 39
98

10

■Tokuyama Corporation

34 40

40 41

35 39

11

12

13

■Group companies

27

36

14
（FY）

20
0

7

95

24
10 1
10 3

21
11 1
1
8

10

11

FY201294
2.7

FY201370
2.4（Millions of metric tons）
180
40■ Dichloromethane (methylene chloride) ■ Chloroform■ 1,2-dichloroethane ■ Chloroethylene (vinyl chloride)

47

28

FY2011108
2.8

FY201490
2.6

Industrial Effluent Amounts and COD Levels

8060FY2010110
2.3

NitrogenPhosphorus

27
11
3
10 3

5
14 2
9 2
5
2
10 2

12

13

23

14（FY）

128

30

25.6

20
10
0

（Metric tons）
200

123

123

24.3

24.9

134
110
22.1

24.1

14.3

90

150
100
50

11
12
13
14
10
■Industrial eﬄuent
COD level （FY）

0

COD level

Among all of the substances Tokuyama handled in fiscal 2014,

Industrial eﬄuent≫ Amounts of PRTR-Designated Substances

SOx, NOx and Soot Emissions＊ Chemical oxygen demand is an indicator used to measure water quality, andrefers to the amount of oxygen required to oxidize organic compounds in water.

Practice of Environmental
Management

Special Features

Site Reports

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Detailed Data

10

Third-Party Review● Performance in Fiscal 2014
● Environmental Accounting● Measures to Help Combat Global Warming● Reducing Atmospheric Emissions and Water Pollution● Recycling and Reducing Waste

Practice of Environmental Management

made in reusing waste and reducing the amount generated, theCompany again achieved its“zero emissions”target of 99.9% in(metric tons)

waste it generates. As a result, the Company maintained a≫ Management and Treatment of PCB Waste

94.0% effective utilization rate of waste and again hit its“zeroThe Tokuyama Group has stopped using all of its remaining 30

emissions”target of 99.9% in fiscal 2014.

transformers and capacitors containing high concentrations ofpolychlorinated biphenyl (PCB).* Of these, 26 were disposed of≫ Waste Management

in fiscal 2014. Other high-level and low-level PCB waste is stored

Tokuyama generated a total of 355,000 metric tons of waste

and managed in compliance with Japan’s Law concerning Spe-in fiscal 2014. It actively worked to recycle this waste both incial Measures for Promotion of Proper Treatment of PCB Wastes.

and outside the Company, mainly by re-using waste matter as
raw materials and fuel for cement at the Tokuyama Factory.
In addition, packing materials, pallets and other wood waste
were crushed and then used as fuel for power plants. Throughits diligent efforts to recycle waste as raw material for cement,
Tokuyama achieved an effective utilization rate of 94.0%, on
par with the previous fiscal year. Moreover, owing to progress

Breakdown of Industrial Waste Treatment in Fiscal 2014
Incinerated waste

Waste sent to landfills

6.0%

0.1%

21.3

21.9

Total waste generated

355.2

Incinerated in-house

311.7

312

“Zero emissions” rate

20.4

30,000

Amount of waste recycled (in-house and externally)
×100
Total waste generated“Zero emissions” rate (%) =1-

Amount of landfilled waste (onsite and offsite)
Total waste generated

×100

99.9

99.9

93.5

94.4

94.7

94.7

93.9

（％）

100
80
60
40

10,000

430

0

90

10

Landﬁll amount (metric tons)

500

330

280

11

12

13

Eﬀective utilization rate

20

320
14

(FY)

0

“Zero emissions” rate

Amount of Recycled Waste（1,000 metric tons）（1,000 metric tons）

2,500
1,550

1,500

500
0

1,430

1,610

1,720

70

54

67

1,879

66

125
1,712

100

76

75
50
25

4

91

10

11

12

Amount for material recycling

13

14（FY）

0

Amount for thermal recycling

Amount of Waste Byproducts Used in Cement（Kilograms per metric ton of cement）

23.1

Recycled externallyEffective utilization rate (%) =

99.9

0

In-house

Waste disposed offsite(Unit: 1,000 metric tons)

99.9

20,000

500

355

99.9

36,260Landﬁlled onsite

87.8%

Total waste
generated

76.9

40,0002,000(unit: 1,000 metric tons)

82.4

1,000

Recycled in-house
Waste recycled
in-house(re-used as raw materials)

6.2%

Effective utilization rate
93.9％

Flow of Industrial Waste Treatment

0.3

Waste recycled externally

99.9％＊ PCB is an organic chlorinated compound that emits dioxins when burned at a lowtemperature. It was formerly used in transformers, capacitors, and many otherelectric products because of its excellent electrical properties, including chemical
stability, thermal resistance, chemical resistance, and insulation. Because of its
danger to the human body, however, it was banned from production and usage
in 1972. Owners of transformers, capacitors, or other products containing PCB
are responsible for their storage at suitable facilities.

50,000Eﬀective utilization rate / “zero emissions” ratefiscal 2014.

Tokuyama makes exhaustive efforts to reduce and recycle theAmount of Waste Sent to Landfills and Rate ofEffective Utilization

Landﬁll amount

Recycling and Reducing Waste

21.9

Outside the Company

Incinerated externally

0.9

Landﬁlled offsite

0.3

400
300

430

446

458

461

448

10

11

12

13

14 （FY）

277

200
100
0

91

Practice of Environmental
Management

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Detailed Data

11

Third-Party Review● Performance in Fiscal 2014
● Environmental Accounting● Measures to Help Combat Global Warming● Reducing Atmospheric Emissions and Water Pollution● Recycling and Reducing Waste

Practice of Environmental Management

The Nanyo Plant’s Cement Production
Recycling System

Local governments
Yamaguchi Eco-tech
Corporation

Incinerated ash

Raw material crusher
Preheater
Raw material powder silo

Raw material dryer

Outside corporations
Waste plastics

Local governments
Sewage sludge

Natural resources
Limestone
Outside corporations
Silica stone

Coal ashIn-house

Outside corporations

Coal ashIn-house
Preincineration

Outside corporations

Clinker silo

Waste liquid
In-house
Organic sludge

Slag

Waste plastics

Organic sludge

Finishing crusher

Rotary kiln

Sludgeクーラー

Construction waste soil

Natural resources

Coal crusher

Coal
In-house

Outside corporations

Incombustible lime

Waste carbon

SludgeCement silo
Outside corporations
GypsumIn-house

Construction waste soil

GypsumCement shipment

Main raw materials

Main energy source

Alternative raw materials

Alternative energy sources

Special Features

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Management

Site Reports

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Detailed Data

12

Third-Party Review● Tokuyama Factory● Kashima Factory● Group Company Reports

Tokuyama Factory

Location:
1-1, Mikage-cho, Shunan City, Yamaguchi 745-8648, Japan
Number of employees: 1,561
Total site area:
1.91 million ㎡
Cement, inorganic chemical products, organic chemical products,
Main products:
polycrystalline silicon, fumed silica, polyvinyl chloride, and otherproducts

Hideki Adachi

Tokuyama Factory
General Manager

Still situated at the Company’s first business site, the Tokuyama Factory is the Group’s main manufacturing facility, and its products account for about 90% of non-consolidated sales. The factory
operates with the motto,“Go to work healthy and return home happy.”Aiming to achieve 12.4
million accident-free hours at the factory and 9 million accident-free hours at its contractors, theEmissions and Transfer of Specific PRTR-DesignatedSubstances in Fiscal 2014

factory is working hard to keep everyone on site happy and safe at work. In fiscal 2015, the factory’s top priorities include: (1) raising risk awareness by expanding“risk simulation”education andtraining programs to all employees; (2) discussing accident case studies to identify their causes andfind ways to prevent them; and (3) dialoguing on safety with contractors, and providing feedbackon the results.

Performance Data
Unit

FY2010FY2011FY2012FY2013

FY2014

SOx emissions Metric tons

metric tons

1,630

2,180

1,450

750

550

NOx emissions

metric tons

8,000

8,600

8,400

9,200

8,850

Soot emissions

metric tons

148

191

190

174

135

Substance Name

Regulatory
Number

Unit: metric tons (mg-TEQ equivalency for dioxins)

Amount of Emissions
Atmospheric

Water

Soil

Subtotal

AmountTransferred

Chloroethylene (vinyl chloride)

94

5.0

0.0

0.0

5.0

0.0

1,2-Dichloroethane

157

4.9

0.0

0.0

4.9

0.5
36.6

Toluene

300

3.9

0.0

0.0

3.9

Chloromethane (methyl chloride)

128

3.0

0.0

0.0

3.0

0.0

Cresol

86

0.0

2.8

0.0

2.8

0.0

1

0.0

1.7

0.0

1.7

0.0

Dichloromethane (methylene chloride)

Water-soluble compounds of zinc

186

1.5

0.0

0.0

1.5

0.0

Chloroform

127

0.9

0.0

0.0

0.9

0.0

1,2-Epoxypropane (propylene oxide)

68

0.6

0.0

0.0

0.6

2.3
183.7

Industrial water consumption

Million metric tons

40.5

43.8

41.3

42.2

41.7

1,2-Dichloropropane

178

0.4

0.0

0.0

0.4

Effluent discharged

Million metric tons

25.5

24.2

24.8

22.1

23.9

Carbon tetrachloride

149

0.1

0.0

0.0

0.1

0.0

COD level

metric tons

124

119

119

132

110

2,2-Azobisisobutyronitrile

16

0.0

0.0

0.0

0.0

0.0

Total nitrogen discharged

metric tons

110

108

94

70

89

Water-soluble copper salt

272

0.0

0.0

0.0

0.0

5.4

Total phosphorous discharged

metric tons

2.3

2.8

2.7

2.4

2.6

Hydrazine

333

0.0

0.0

0.0

0.0

0.0

PRTR-designated substance emissions

metric tons

37

32

39

33

34

Waste generated

Thousand metric tons

312

379

381

395

354

Waste sent to landfills

metric tons

417

490

320

277

313

Energy consumption*

Thousand gigajoules

49,80052,40044,10043,70044,200CO2 emissions* (originating from fossil fuel)Thousand metric tons

4,510

4,730

4,020

4,020

4,040

Complaints

Cases

5

3

0

1

0

* In accordance with a revision of Japan’s Act on the Rational Use of Energy, figures based on calorific values and other factors have beenrecalculated retrospectively to 1990.

Hydrogen fluoride and its water-soluble form

374

0.0

0.0

0.0

0.0

0.0

Benzene

400

0.0

0.0

0.0

0.0

0.0

Boron compounds

405

0.0

0.0

0.0

0.0

0.1

Dioxins

243

8.0

1.4

0.0

9.4

0.0

20.2

4.5

0.0

24.7

228.5

Total (excluding dioxins)

Substances are listed in descending order of emissions levels; substances with no emissions are listed in order of the regulatory number
Water refers to public waters.
Amount transferred indicates the sum of the quantity transferred to sewage systems and the quantity subject to intermediate treatment.
Total figures have been rounded to the first decimal place.

Special Features

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Management

Site Reports

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Detailed Data

13

Third-Party Review● Tokuyama Factory● Kashima Factory● Group Company Reports

Kashima Factory

Location:
26 Sunayama, Kamisu City, Ibaraki 314-0255, Japan
Number of employees: 78
Total site area:
101,000㎡
Produced by Tokuyama Corporation
Main products:
Bulk pharmaceuticals for X-ray contrast agents, stomach and duodenal
ulcer treatment drugs, and diabetes drugs; optical materials (plastic
lens monomer, light modulating materials, and hard coating solutions);
raw materials for electronic materials; metal cleaning solvents
Produced by Tokuyama Dental Corporation
Dental materials (restorative materials, adhesives, relining materials,
impression materials and investment materials)

The Kashima Factory strives to recycle waste matter while placing the utmost importance on theproper management and handling of chemical substances.

Substance Name

Looking ahead, the Kashima Factory is examining the feasibility of material and thermal recycling as it works to increase its effective utilization rate for all types of waste matter.
Waste sent to landfills for final disposal amounted to 11 metric tons, and the Company
achieved its“zero emissions”target of 99%.
Meanwhile, Tokuyama Dental Corporation modified the operating conditions of treatment

Kashima Factory
General Manager

Emissions and Transfer of Specific PRTR-DesignatedSubstances in Fiscal 2014

As a result of this approach, the factory achieved an 80% effective utilization rate of waste infiscal 2014, maintaining the high recycling rate achieved in the previous fiscal year.

Fumiaki Iwasaki

Regulatory
Number

Unit: metric tons (mg-TEQ equivalency for dioxins)

Amount of Emissions
Atmospheric

Water

Soil

Subtotal

AmountTransferred

Chloroform

127

1.1

0.3

0.0

1.5

36.2

Toluene

300

0.4

0.0

0.0

0.4

15.4

Dichloromethane

186

0.4

0.0

0.0

0.4

2.3

Acetonitrile

13

0.0

0.0

0.0

0.0

1.3

equipment to eliminate handling in certain processes in an effort to reduce its atmospheric

α-Methylstyrene

149

0.0

0.0

0.0

0.0

0.0

emissions of exhaust gases. Consequently, the company maintained the same level of share of

1,4-Dioxane

150

0.0

0.0

0.0

0.0

0.1

total atmospheric emissions from the factory with fiscal 2014.

Performance Data
Unit

N,N-Dimethylacetamide

213

0.0

0.0

0.0

0.0

4.2

N,N-Dimethylformamide

232

0.0

0.0

0.0

0.0

13.1

Triethylamine

277

0.0

0.0

0.0

0.0

0.0

2-Vinylpyridine

338

0.0

0.0

0.0

0.0

0.2

417

FY2010FY2011FY2012FY2013

FY2014

Industrial water consumption

Thousand metric tons

77

71

76

51

48

Methacrylic acid 2,3-Epoxypropy

Effluent discharged

Thousand metric tons

93

90

96

66

63

Total

COD level

metric tons

4

4

4

3

3

Notes: All figures are the numerical sum for Tokuyama Corporation and Tokuyama Dental Corporation.

PRTR-designated substanceemissions

metric tons

2

2

1

2

2

Waste generated

metric tons

857

909

930

919

1,020

Waste sent to landfills

metric tons

12

7

7

7

11

Energy consumption*

Thousand gigajoules

60

57

59

36

36

CO2 emissions* (originating fromfossil fuel)metric tons

2,340

2,324

2,399

2,476

2,465

Complaints

Cases

0

0

0

0

0

＊ In accordance with a revision of Japan’s Act on the Rational Use of Energy, figures based on calorific values and other factors have beenrecalculated retrospectively to 1990.

0.0

0.0

0.0

0.0

0.0

2.0

0.3

0.0

2.3

72.7

Substances are listed in descending order of emissions levels; substances with no emissions are listed in order of the regulatory number Water refers to public waters.
Amount transferred indicates the sum of the quantity transferred to sewage systems and the quantity subject to intermediate treatment.
Total figures have been rounded to the first decimal place.

Special Features

Practice of Environmental
Management

Site Reports

Site Information

Detailed Data

14

Third-Party Review● Tokuyama Factory● Kashima Factory● Group Company Reports

Tokuyama recognizes that its group companies must be fully engaged with the issues addressed by its Responsible Care
activities. The Company has concluded a CSR Management Agreement with its manufacturing subsidiaries in and outsideof Japan and is providing them with assistance to carry out these activities. The Company collects data from group companies on their environmental impact, safety management, and other indicators, and conducts safety, environmental, andquality audits at several subsidiaries each year. In this way, Tokuyama is closely following the Responsible Care activities at
each company and ensuring that they are complete. Tokuyama also shares news on regulatory trends and other relevant

11 Group Companies with ISO 9001 and/or ISO 14001 Certification
Group Company

ISO9001

ISO14001

ISO9001

ISO14001

Sun·Tox Co., Ltd.

•

Tokuyama Siltech Co., Ltd.

•—Sun Arrow Kasei Co., Ltd.

—••ASTOM Corporation•

Shin Dai-ichi Vinyl Corporation—

Figaro Engineering Inc.

•
•
•
•*
•

•
•
•
•
•

Tokuyama Dental Corporation—*

Excel Shanon Corporation
Tohoku Shanon Corporation
A&T Corporation—•

information with its group companies, and helps them acquire ISO 9001 and ISO 14001 certification.

Sun ·Tox Co., Ltd.

Established: February 14, 1992
Shareholder: Tokuyama Corporation (100%)polypropylene films and cast polypropylene films,

Kazunori Shimada

Tokuyama Polypropylene Co., Ltd.
•
• = Acquired certification
Certification acquired by a worksite of the group company• == Acquired
ISO 13485 certification*

Head office:Akasaka Enoki-zaka Mori Building, 1-7-1 Akasaka, Minato-ku, Tokyo, Japan
Business activities: Manufacture and sale of biaxial-oriented polypropylene films and cast polypropylene films

Sun·Tox’s Kanto Plant manufactures biaxial-oriented

Kanto Plant

Group Company

Sun·Tox’s Tokuyama Plant manufactures environmen-

Tokuyama Plant

tally friendly biaxial-oriented polypropylene films, which

which are used for food packaging and other appli-

are mainly used for food and beverage packaging,cations, totaling about 28,000 metric tons annually.

amounting to about 23,000 metric tons annually.

As a Type 1 Designated Energy Management Factory

As part of its environmental initiatives, the plant isunder the Japan’s Act on the Rational Use of Energy,

actively working to reduce per-unit energy consump-

the Kanto Plant strives to cut down on its overall energy

tion and increase recycling rates. With respect toconsumption on a per-unit basis.

Naoki Ueda

The plant also conducts initiatives to improve

Plant Manager

Plant Manager

safety, it acquired OSHMS certification in 2013 for allof its departments including R&D departments. Un-

productivity and reduce waste, and actively interacts

der the slogan,“Strictly following safety procedures,with its local community by participating in cleanup

making manufacturing enjoyable, and never compro-

activities within the industrial park wher it is located.

mising quality,”the plant aims to keep its facilities

As it continues to implement three management sys-

operating safely so it can be depended upon by thetems, namely Japan’s Occupational Safety and Healthcommunity, customers and employees.

Management System (OSHMS), ISO 14001, and ISO
Location: 3075-18 Shimasu, Itako City, Ibaraki, Japan
Number of employees: 185
Total site area: 55,800 m2

9001, the Kanto Plant is building on its achievementswith the aim to be a community-based factory.

Performance Data
Waste generated
Waste sent to landfills
Energy consumption
CO2 emissions
SOx emissions
NOx emissions
Soot emissions

Unit
metric tons
metric tons
Thousand gigajoules
Thousand metric tons
metric tons
metric tons
metric tons

FY2010FY2011FY2012FY2013

FY2014

56

57

26

15

20

38

43

7

4

10

344

341

340

360

351

19

19

19

20

20

0.3

0.4

0.3

0.2

0.3

0.6

0.7

0.6

0.7

0.6

0.04

0.04

0.03

0.06

0.05

Location: 7-7, Harumi-cho, Shunan City, Yamaguchi, Japan
Number of employees: 154
Total site area: 24,100 m2

Performance Data
Waste generated
Waste sent to landfills
Energy consumption
CO2 emissions
PRTR-designated substance emissions
Complaints

Unit
metric tons
metric tons
Thousand gigajoules
Thousand metric tons
metric tons
Cases

FY2010FY2011FY2012FY2013

FY2014

80

70

67

66

76

9

1

2

2

1

434

448

445

463

458

26

26

26

27

27

0.1

0.0

0.0

0.0

0.0

0

0

0

0

0

Practice of Environmental
Management

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Site Reports

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Detailed Data

15

Third-Party Review● Tokuyama Factory● Kashima Factory● Group Company Reports

Sun·Arrow Kasei Co., Ltd.

Tokuyama Polypropylene Co., Ltd.

Established:
Shareholder:
Head office:Business activities:

Established:
Shareholder:
Head office:Business activities:

February 1, 1999
Tokuyama Corporation (100%)
Nakanoshima Central Tower, 2-2-7 Nakanoshima, Kita-ku, Osaka, Japan
Manufacture and sale of polyvinyl chloride compounds

Sun Arrow Kasei’s Tokuyama Plant manufactures andTokuyama Plant

sells polyvinyl chloride compounds used for pipes,

April 2, 2001
Tokuyama (50%), Prime Polymer Co., Ltd. (50%)
1-1 Harumi-cho, Shunan City, Yamaguchi, Japan
Manufacture and sale of polypropylene resin and flexible polypropylene resin

Tokuyama Polypropylene’s Tokuyama Plant conducts

Tokuyama Plant

risk assessments of processes, facilities, and opera-

joints, and other items essential for upgrading infra-

tions, and takes measures to identify near-miss situa-

structure, as well as resin window frames, which aretions and points of concern, in order to enhance theplant’s safety culture. The result has been a perfect

highly effective for saving energy.

Yasuto Yasuzawa
Plant Manager

The plant practices ISO 14001 environmental

accident- and disaster-free record since the time it was

management, and ensures safet y and prevents

first established as Tokuyama’s polypropylene film

accidents by having all employees participate inbusiness 39 years ago.

Hiroaki Endo

activities designed to eliminate problems, identify

The plant is scheduled to obtain recertification in

Plant Manager

near-miss situations, and practice the 5S principles.

2015 under the High Pressure Gas Safety Act and the

Owing to this approach, the plant has maintained an

Ordinance on Safety of Boilers and Pressure Vessels,

accident- and disaster-free record for 15 years sinceand is pursuing Responsible Care activities with theits establishment.

goals of extending its accident- and disaster-free re-In fiscal 2015, the plant intends to strictly en-cord, reducing its environmental impact, and eliminat-

force internal controls while carrying out Responsi-

ing customer complaints related to quality.

ble Care activities based on a safety-first policy for
all operations.
Location: 1-1, Harumi-cho, Shunan City, Yamaguchi, Japan
Number of employees: 62
Total site area: 70,997 m2

Location: 1-2 Harumi-cho, Shunan City, Yamaguchi, Japan
Number of employees: 24
Total site area: 3,280 m2

Performance Data
Unit

FY2010FY2011FY2012FY2013

FY2014

Power consumption

Thousand kilowatt hours

2,735

2,763

2,455

2,562

2,473

Waste plastic produced

metric tons

124

110

107

125

108

Waste plastic effectively usedmetric tons

124

110

107

124

105

Waste sent to landfills offsite for disposal

metric tons

12.5

10

15

7

8

Steam usage

metric tons

240

240

240

240

240

Industrial water consumption

Thousand metric tons

65

65

65

65

65

Performance Data
Unit

FY2010FY2011FY2012FY2013

FY2014

Industrial water consumption

Thousand metric tons

329

366

343

411

308

Waste generated

metric tons

180

123

160

116

89

Waste sent to landfills
Unit Energy Consumption Index(Fiscal 2002=100)

metric tons

3.8＊

0

1.9＊

15

2.4＊

%

86

88

88

84

76

＊ Year with periodic maintenanceSpecial Features

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Management

Site Reports

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Detailed Data

Third-Party Review

16

Tokuyama Malaysia Sdn. Bhd.

Tokuyama Chemicals (Zhejiang) Co., Ltd.

Established:
Shareholder:
Head office:Established:
Shareholder:
Head office:Business activities:

August 18, 2009
Tokuyama Corporation (100%)
Lot 600, 6th Floor, Wisma Bukit Mata Kuching, Jalan Tunku Abdul Rahman, 93100 Kuching,
Sarawak, Malaysia
Business activities: Manufacturing and sale of polycrystalline silicon
Location:Lot 89, Block 1, Kemena Land District, Samalaju Industrial Park, 97300 Bintulu, Sarawak, Malaysia

Takeo Suzuki
President

September 13, 2005
Tokuyama Corporation (100%)№ 555 Yashan West Rord, Economic Development Zone Zhapu Port, Jiaxing, Zhejiang China 314201
Manufacturing and sale of fumed silica, Trichlorosilane , Tetrachlorosilane, and 31% hydrochloric acid

Masaki Yoshinaga
President

Special Features

Practice of Environmental
Management

Site Reports● Environmental Data for Tokuyama● Emissions of SOx, NOx, and Soot

Site Information

Detailed Data

17

Third-Party Review

Environmental Data for Tokuyama
Input (Unit: 1,000 metric tons)

FY2010FY2011FY2012FY2013

FY2014Comparison with the previous fiscal year (%)● Discharge of Nitrogen and Phosphorous

Waste and by-products

1,500

1,680

1,780

1,945

1,790

-8.0

● Waste Management

Fuel

2,020

2,270

2,150

1,760

1,820

3.4

● Energy Consumed on a Per-Unit Basis at the Tokuyama Factory

Raw materials

5,390

5,880

5,650

6,080

5,900

-3.0

● Amount of Waste Matter and By-Products Used to Produce Cement

Industrial water

40,50043,90041,30042,20041,700-1.2● Material and Thermal Recycling Amounts in Cement Production

Output (Unit: 1,000 metric tons)● Energy Consumption

Carbon dioxide● Emissions of CO2

FY2010FY2011FY2012FY2013

FY2014Comparison with the previous fiscal year (%)

6,170

6,510

5,800

5,930

5,910

-0.5

Waste (incinerated and landfill)

20

21

20

21

22

4,8

● Emissions of PRTR-Designated Substances

Substances with environmental impact

10

11

10

10

10

0.0

● Emissions of Hazardous Air Pollutants

Process effluent

25,60024,30024,90022,10024,000

8.6● Discharge of Industrial Effluent and Levels of COD● Breakdown of Waste Treatment Methods● Landfilled and Recycled Waste

Emissions of SOx, NOx, and Soot
Unit: Metric tons

FY2010FY2011FY2012FY2013

FY2014Comparison with the previous fiscal year (%)

SOx

1,630

2,180

1,450

750

550

-26.7

NOx

8,000

8,600

8,400

9,200

8,850

-2.8

Soot

148

191

190

174

135

-22.4

Discharge of Nitrogen and Phosphorous
Unit: Metric tons

FY2010FY2011FY2012FY2013

FY2014Comparison with the previous fiscal year (%)

Nitrogen

110

108

94

70

89

27.1

Phosphorous

2.3

2.8

2.7

2.4

2.6

8.3

FY2013

FY2014

Waste Management
Unit: 1,000 metric tons

FY2010FY2011FY2012Comparison with the previous fiscal year (%)

Waste recycled in-house

271

331

337

350

312

-10.9

Waste recycled externally

21.1

27.3

25.0

24.5

21.9

-10.6

Incinerated waste

20

21

19.7

20.5

21.3

3.9

Waste sent to landfills

0.4

0.5

0.3

0.3

0.3

0.0

Special Features

Practice of Environmental
Management

Site Reports● Environmental Data for Tokuyama● Emissions of SOx, NOx, and Soot

Site Information

Detailed Data

18

Third-Party Review

Energy Consumed on a Per-Unit Basis* at the Tokuyama Factory
Unit: %

Base year (FY2005)

FY2012FY2013

FY2014● Discharge of Nitrogen and Phosphorous

Per-unit energy consumption● Waste Management※ The factory has been working since 2014 to reduce per-unit energy consumption in fiscal 2020 by 3.0% compared to the fiscal 2005 level.

● Energy Consumed on a Per-Unit Basis at the Tokuyama Factory● Amount of Waste Matter and By-Products Used to Produce Cement● Material and Thermal Recycling Amounts in Cement Production

100.0

100.0

99.4

Target ( FY2020 )

97.9

97.0

Amount of Waste Matter and By-Products Used to Produce Cement
Unit: Kg per metric ton of cement
Amount used

Base year (1991)

FY2010227

FY2011430

FY2012446

FY2013458

FY2014461

448● Energy Consumption● Emissions of CO2● Emissions of PRTR-Designated Substances● Emissions of Hazardous Air Pollutants● Discharge of Industrial Effluent and Levels of COD● Breakdown of Waste Treatment Methods● Landfilled and Recycled Waste

Material and Thermal Recycling Amounts in Cement Production
Unit: 1,000 metric tons

Base year (1991)

FY2010FY2011FY2012FY2013

FY2014

Material recycling

1,550

1,430

1,610

1,730

1,879

1,712

Thermal recycling

4

67

70

54

66

76

Energy Consumption
Unit: 1,000 gigajoules

Base year (1990)

Tokuyama Corporation

37,60049,90052,50044,20043,70044,400

—

2,800

2,800

2,600

2,800

2,800

Group companies

FY2010FY2011FY2012FY2013

FY2014Emissions of CO2
Unit: 1,000 metric tons

Base year (1990)

FY2010FY2011FY2012FY2013

FY2014

Originating from fuel

3,290

4,510

4,730

4,020

4,020

4,050

Originating from raw materials

1,930

1,420

1,550

1,570

1,680

1,630

Originating from waste matter

20

240

230

210

230

230

200

210

190

200

200

Group companies

Special Features

Practice of Environmental
Management

Site Reports● Environmental Data for Tokuyama● Emissions of SOx, NOx, and Soot

Site Information

Unit: Metric tons
Tokuyama Corporation● Waste Management

Group companies● Amount of Waste Matter and By-Products Used to Produce Cement● Material and Thermal Recycling Amounts in Cement Production● Energy Consumption● Emissions of CO2● Emissions of PRTR-Designated Substances● Emissions of Hazardous Air Pollutants● Discharge of Industrial Effluent and Levels of COD● Breakdown of Waste Treatment Methods● Landfilled and Recycled Waste

19

Third-Party Review

Emissions of PRTR-Designated Substances● Discharge of Nitrogen and Phosphorous● Energy Consumed on a Per-Unit Basis at the Tokuyama Factory

Detailed Data

Base year (1998)

FY2010237

FY2011FY2012FY2013

FY2014

38

34

40

35

27

39

40

41

39

36

Emissions of Hazardous Air Pollutants
Unit: Metric tons

Base year (1995)

Dichloromethane (methylene chloride)

FY201028

FY2011
3

FY2012
1

FY2013
3

FY20142

1.5

Chloroform

7

1

1

3

2

2.1

1,2-Dichloroethane

47

10

8

10

10

4.9

Chloroethylene (vinyl chloride)

21

10

11

11

9

5

Discharge of Industrial Effluent and Levels of COD
Base year (1990)

FY2010FY2011FY2012FY2013

FY2014

Industrial effluent (million metric tons)

14.3

25.6

24.3

24.9

22.1

24.1

COD (metric tons)

180

128

123

123

134

112

Breakdown of Waste Treatment Methods
Unit: 1,000 metric tons

FY2009FY2010FY2011FY2012FY2013

FY2014

Waste recycled in-house

260

271

331

337

350

312

Waste recycled externally

20.8

21.1

27.3

25

24.5

21.9

Incinerated waste

18.9

20

21

19.7

20.5

21.3

Waste sent to landfills

0.4

0.4

0.5

0.5

0.3

0.3

Total waste generated

300

313

380

382

396

355

Landfilled and Recycled Waste
Base year (1990)
Landfilled waste (1,000 metric tons)

FY2010FY2011FY2012FY2013

FY201436,260

430

500

330

280

320

Effective utilization rate (%)

77

93.5

94.4

94.7

94.7

93.9

“Zero emissions” rate (%)

82

99.9

99.9

99.9

99.9

99.9

Special Features

Practice of Environmental
Management

Site Reports

Site Information

Detailed Data

20

Third-Party Review

A Review of Tokuyama’s
CSR Report and Corporate Profile 2015

In Response toThird-party Review

Eriko Nashioka
Representative Director, Institutefor Environmental Management
Accounting, Certified Public
Accountant and Certified Tax
Accountant, and part-time lecturer
in environmental accounting andenvironmental auditing for the Facultyof Commerce, Doshisha University

Toshihiko Annaka≫ Creation of Value
A company’s social role depends on what sort of value it creates, and how it contributes to society. The Tokuyama Group,

Executive Officer,
and General Manager,
Corporate Social Responsibility
Divisionacting in line with its philosophy of being“responsive to society,”has always had a clear picture of what society expects of
it, and leverages the power of chemistry to make a unique contribution. One indicator of how important the Tokuyama GroupThe Tokuyama Group now presents its CSR Report and Corpo-≫ Still Rock-Solid after Nearly a Century

is to society is the fact that it has many products for which it israte Profile as a single document to help stakeholders gain athe only producer in Japan, or for which it enjoys No.1 global

more accurate understanding of its direction and the founda-

The Tokuyama Group formulated a Centennial Vision a few

market share. This means that Tokuyama bears a responsibilitytion that supports its progress. With the appointment of a newyears ago in preparation for 2018, the 100th anniversary of its

to provide its products without fail — and it makes socially re-president in March 2015, the report presents his views on thefounding, and has been busy with related activities since then.

sponsible management all the more important.

Group’s management, describes our focus on the customer’sIn fiscal 2014, however, the Group recorded a major loss as

The Integrated Reporting framework encourages compa-

perspective and our top technologies, and features our ongoing

the result of an impairment loss at Tokuyama Malaysia. Consid-

nies to show how their business models create value overefforts for safety and socially responsible management. The

ering how careful companies are about their financial position,

the medium and long terms based on six kinds of capital. The

special features provide information on the safety initiatives

I think only a very safe company can take decisive action like

Tokuyama Group regards CSR as the foundation of its busi-

at our cement plants, and the RC Research Department which

this. The Tokuyama Group deeply values safety, and this will

ness, so I hope that the Group would enhance clarity by doing

supports the Group’s environmental analysis and R&D.

be evident to readers. I see several reasons that Tokuyama has

three things: put forward a business model that contributes

As for Integrated Reporting and the medium- to long-

been able to stay in business for almost a century, not least of

to the resolution of social issues; clearly state the importanceterm business model that makes use of six kinds of capital,

which are its emphasis on safety and the trust it has earned

and priority of its initiatives; and disclose benchmarks to indi-

we have been focusing on providing information on how ourfrom employees and the public by consistently responding tocate the progress of its initiatives.

systems and initiatives are built. In the future we will consid-

society’s expectations. Tokuyama’s efforts to reduce CO2 emis-

I suggest that the Group consider disclosing benchmarks

er the possibility of disclosing benchmarks on CSR initiatives

sions and waste, described in this report, have also played an

on CSR initiatives, just like financial benchmarks, to make it

to help stakeholders get a clear picture of exactly what we

important role.

easier for people to understand the Tokuyama Group.

have achieved.