FY 2020 CSR website Site Reports > Zeon Corporation – Tokuyama Plant

Zeon Corporation – Tokuyama Plant
Tokuyama Plant Profile
Main Products
Butadiene monomers, synthetic rubbers, synthetic latex, polymerized toners,
single-walled carbon nanotubes
Established in 1965, Tokuyama Plant is the main Zeon production plant forsynthetic rubber using butadiene monomer extracted from naphtha. Approximately
half of the synthetic rubbers it produces are exported from the nearby Port of
Tokuyama to Europe, Asia, and other parts of the world. In 2015, Tokuyama Plant
successfully mass-produced single-walled carbon nanotubes, a world first.

Aerial view of Tokuyama Plant

Environment and Safety Policy
The Tokuyama Plant has formulated the following environment and safety policy,
based on being a petrochemical plant that handles high-pressure gases as well as hazardous and poisonous substances, andwhich is located in the Shunan Industrial Zone near residential areas and railway lines.
1. With the participation of all employees, we are committed to maintaining safe and reliable operations and to being a plant thatis trusted by everyone in the local community.
2. We set targets and conduct activities in the areas of the environment, safety, and occupational health and safety; we aim toimprove our various management systems on an ongoing basis, so as to enhance our environmental and safety
performance.
3. We identify all sources of danger in the workplace, and by reducing and eliminating them, we aim to achieve zero occurrenceof environmental and safety incidents and occupational accidents.
4. We strive to prevent environmental contamination and conserve energy, to help protect the environment.
5. We comply with environment- and safety-related laws and regulations, agreements, and internal rules and regulations; wealso strive to maintain and improve our level of environmental and safety performance.
6. We strive to maintain and improve the physical and mental health of all employees, and to create a vibrant and engaging
workplace.

Plant Policy by the Plant ManagerPolicy
The Tokuyama Plant engages with the local community and actively participates solutions tosocial issues with strong local ties with the aim of gaining the trust of society. To achieve this, theplant engages in dialog centered on production innovations, the foundations of production activities,
exchanges knowledge, and continuously strives to be a safe and secure plant. Each employee
works with a positive and enthusiastic attitude so that the Tokuyama Plant can be a plant where
employees can enjoy their work and feel a sense of reassurance.

Tokuyama Plant Manager
Masao Akasaka

Safety Initiatives
PolicyLearn from examples and actual work, act with a sense of ownership, and achieve zero accidents and disasters.
Specific Initiatives
・Firmly establish and maintain four types of safety activities (risk awareness activities, activities relating to near-miss incidents,
foolproofing activities, and risk assessment activities in relation to operations and chemical products) and enhance the cultureof safety.
・Learn from examples and actual work and promote autonomous safety activities-1-

FY 2020 CSR website Site Reports > Zeon Corporation – Tokuyama Plant

Environmental Impact Reductions
PolicyAchieve our reduction targets for per-unit energy consumption and per-unit CO2 emissions.
(1) Investigate the introduction of energy-saving technologies(2) Reinforce day-to-day management of energy consumption and CO2 generation
Scope of Environmental Management System(1) Organizational unit : Departments of the Tokuyama Plant, Zeon Corporation
Function: Manufacturing of synthetic rubbers, synthetic latex, film materials, and carbon nanotubes, and pilot
research on synthetic rubbers and thermoplastic resins
Physical boundary : The entire area of the Tokuyama Plant, Zeon Corporation, 2-1 Nachi-cho, Shunan City, Yamaguchi
Prefecture(2) Organizational: Business processes from raw materials procurement through to manufacturing, packaging,
activities
storage and shipping, and utility operations
Products and: Synthetic rubbers, synthetic latex, film materials and carbon nanotubes, providing information toservices
customers, and responding to complaints from customers and local residents(3) Authority and: Head Office divisions (including design and development), partner companies (product logistics,capacity ofdisposal of industrial waste, etc.), vendors (companies supplying raw materials, etc.)
managing andinfluencing
organization
Specific Initiatives
1. Reducing emissions of hazardous chemical substances
・We are striving to control emissions of PRTR substances through production process improvements and the effective
operational management and monitoring of exhaust gas purification equipment.
2. Reducing industrial waste
・We are continuing to maintain our record of zero waste sent to landfills by practicing the 3R’s (Reduce, Reuse, and Recycle) inrelation to industrial waste.
3. Conserving resources and energy
・We are working to improve our per-unit energy consumption through day-to-day management and problem identification by
the Plant’s Energy Conservation Working Group and Energy Conservation Promotion Committee, and through theimplementation of technological counter-measures in collaboration with Zeon’s head office.
4. Reducing impacts on air quality and on water quality
・We are striving to reduce our NOx, SOx, and CO2 emissions through stable operation of boiler equipment.
・We are striving to reduce our COD and total nitrogen emissions through effective operational management and monitoring ofwastewater treatment facilities.
5. Environmental Data * “0” indicates less than 0.5 tons, and “0.0” indicates less than 0.05 tons
Tokuyama Plant
FY 2015
FY 2016
FY 2017
Butadiene consumption (tons)
Hazardoussubstances

FY 2018

FY 2019

195,538152,247

179,158

142,574

170,882

0.7

1.6

0.8

0.8

1.0

16,983

13,476

19,06016,654

18,769

0.6

0.6

0.6

0.6

0.6

422,439

347,496

412,431

342,547

397,462

2.1

2.9

3.0

1.9

2.4

23,16324,73828,89825,49623,063

4,737

5,208

4,932

5,222

4,080

0.0

0.0

0.0

0.0

0.0

Butadiene emissions (tons)
Acrylonitrile consumption (tons)
Acrylonitrile emissions (tons)

Substances
subject to thePRTR Act
Industrial
waste

Consumption (tons)
Emissions (tons)
Amount generated before compacting(tons)
Amount generated after compacting(tons)
Amount sent to landfills (tons)-2-FY 2020 CSR website Site Reports > Zeon Corporation – Tokuyama Plant

CO2 emissions (tons)

263,215

228,574

261,456

231,443

258,305

SOx emissions (tons)

622

603

796

689

770

NOx emissions (tons)

191

200

256

216

224

Soot emissions (tons)

10.9

4.3

7.3

3.8

6.1

Water resource consumption (1,000 m3)

8,812

8,703

8,705

7,852

8,063

8,051

8,148

8,206

7,457

7,576

COD emissions (tons)

5749

52

47

61

Total phosphorus discharge (tons)

0.8

0.7

0.6

0.5

0.7

Total nitrogen discharge (tons)

28252622

30

104,326

93,669105,323

93,430102,984

85%

96%

92%

97%

93%

603,368

532,374

626,406

527,914604,514

Atmosphericemissions(industrial water + groundwater + waterworks)

Total wastewater discharge (1,000 m3)
Wastewater

EnergyConsumption (crude oil equivalent,kL)
Unit consumption index (FY 1990 = 100)

Production equivalent (tons)

Relationship with Employees
Human Resource Development Policy
At Tokuyama Plant, we develop human resources through education programs designed to draw out, develop, and mobilize
the potential of employees, based on the ideal of employees “working toward ambitious goals, always thinking things throughand taking action independently, and remaining open to change.”
Specific Initiatives
・We implement employee education and training based on an education scheme that covers basic education, environmental
and safety education, vocational education, quality management education, obtaining qualifications, and personaldevelopment.
・Basic education at the Monozukuri Training Center in the Mizushima Plant for employees in their first to third years ofemployment
・Transfer of specialized techniques and skills and developmental education
・Grade-specific education
・Support for obtaining qualifications

Relationship with the Local Community
Specific Initiatives
1. Contributing to the community through volunteering・Beautification activities in the area surrounding the plant・Higashikawa Cleanup Campaign
・Tree thinning in the forest that is the industrial water source, conducted jointly with othercompanies that use the industrial water and forest operators
2. Interactions with the local community
Higashikawa Cleanup Campaign
・Zeon Waraku Odori Dance FestivalWe have held the festival since 1974 to deepen interaction with employees’ families andcommunity residents. Approximately 2,000 people participated this year.
・Participate in Responsible Care Council community dialogue events (twice/year)
We provide reports on our Responsible Care activities, including environmental improvements and safety measures, to local
authorities and community representatives.
・Experimental classroom (making a super ball) (twice/year)-3-

FY 2020 CSR website Site Reports > Zeon Corporation – Tokuyama Plant

3. Plant tours
・Plant tours
Held in conjunction with Japan Responsible Care Council community dialogue events Leaders of residents' associations
near the plant participated in the tours
・Summer vacation parent and child classroom (organized by the Chamber of Commerce and Industry)
Plant bus tours (twice/year)
・Plant tours for junior high school and senior high school students-4-