FY 2019 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-walledcarbon nanotubes
Established in 1965, Tokuyama Plant is the main Zeon production plant for synthetic 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, andother parts of the world. In 2015, Tokuyama Plant successfully mass-produced single-walledcarbon 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, and which 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
With production innovations driving plant reforms, we cooperate with the two Zeon Group
companies of Zeon Yamaguchi Co., Ltd. and Zeon North Co., Ltd. to realize stable and safe plant
operations and deepen our roots in the local community.
With the motto of “greetings and the 3S’s (sort, straighten, and scrub) are the foundation ofeverything we do,” we pursue dynamic and forward-looking plant operations with the participationof all employees in production innovations.
We aim to gain the trust of society by making contributions to resolving social
issues and having employees engage with the local community.

Safety Initiatives
PolicySafety first! Employees take responsibility for their actions to realize zero accidents and disasters.

-1-Tokuyama Plant Manager
Masao Akasaka

FY 2019 CSR website Site Reports > Zeon Corporation – Tokuyama Plant

Specific Initiatives
・We routinely implement, and are proceeding with the intensification of, four types of safety activities that are implemented on acompany-wide basis (risk awareness activities, activities relating to near-miss incidents, foolproofing activities, and risk
assessment activities in relation to operations and chemical products), and we are also implementing occupational accident
prevention measures.
・We identify manufacturing process hazards (hazard sources) and work to prevent accidents through risk assessment and risk
mitigation activities.

Environmental Impact Reductions
PolicyAchieve our targets for per-unit energy consumption and per-unit CO2 emissions.
(1) We analyze factors causing our energy consumption per unit to deteriorate and devise systems to prevent performance frombacksliding.
(2) We identify ways to conserve energy on an ongoing basis to achieve our mid- to long-term plan.
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 activities: Business processes from raw materials procurement through to manufacturing, packaging, storageand shipping, and utility operations
Products and services: Synthetic rubbers, synthetic latex, film materials and carbon nanotubes, providing information tocustomers, and responding to complaints from customers and local residents(3) Authority and capacity of managing and influencing organization: Head Office divisions (including design and development),
partner companies (product logistics, disposal of industrial waste, etc.), vendors (companies supplyingraw materials, etc.)
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.

-2-FY 2019 CSR website Site Reports > Zeon Corporation – Tokuyama Plant

5. Environmental Data＊“0” indicates less than 0.5 tons, and “0.0” indicates less than 0.05 tons

Tokuyama Plant
Butadiene consumption (tons)
Hazardoussubstances

FY2014FY2015FY2016FY2017FY2018170,327

195,538

152,247

179,158

142,574

1.1

0.7

1.6

0.8

0.8

14,37916,983

13,476

19,06016,654

Butadiene emissions (tons)
Acrylonitrile consumption (tons)

0.7

0.6

0.6

0.6

0.6

397,637

422,439

347,496

412,431

342,547

2.7

2.1

2.9

3.0

1.9

Amount generated before
compacting (tons)

24,06323,16324,73828,89825,496

Amount generated after
compacting (tons)

4,674

4,737

5,208

4,932

5,222

0.0

0.0

0.0

0.0

0.0

CO2 emissions (tons)

237,362

263,215

228,574

261,456

231,443

SOX emissions (tons)

507

622

603

796

689

NOX emissions (tons)

179

191

200

256

216

Soot emissions (tons)

2.2

10.9

4.3

7.3

3.8

8,3938,812

8,703

8,705

7,852

7,785

8,051

8,148

8,206

7,457

COD emissions (tons)

4257

49

52

47

Total phosphorus discharge(tons)

0.6

0.8

0.7

0.6

0.5

Total nitrogen discharge (tons)

27

28

25

26

22

Consumption(crude oil equivalent, kL)

92,423

104,326

93,669105,323

93,430

Unit consumption index(FY 1990 = 100)

94%

85%

96%

92%

97%

537,497

603,368

532,374

626,406

527,914

Acrylonitrile emissions (tons)
Substances
subject to thePRTR Act

Industrial waste

Consumption (tons)
Emissions (tons)Amount sent to landfills (tons)
Atmosphericemissions

3

Water resource consumption (1,000 m )(industrial water + groundwater + waterworks)

Total wastewater discharge(1,000 m3)
Wastewater

EnergyProduction 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 thepotential of employees, based on the ideal of employees “working toward ambitious goals, always thinking things through andtaking 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 for manufacturing operators(1) Education at the Monozukuri Training Center at Mizushima Plant for employees in their first to third years of employment(2) Professional development that transfers operational skills and technical knowledge
・Grade-specific education
・Support for obtaining qualifications-3-FY 2019 CSR website Site Reports > Zeon Corporation – Tokuyama Plant

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, conductedjointly with other companies that use the industrial water and forest operators
Higashikawa Cleanup Campaign
2. Interactions with the local community
・Zeon Waraku Odori Dance Festival
We have held the festival since 1974 to deepen interaction with employees’ families and community residents. Approximately
2,000 people participated this year.
・Participation 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.

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