FY2022 Site Reports > Zeon Corporation – Tokuyama Plant

Zeon Corporation – Tokuyama Plant
Tokuyama Plant Profile
Main Products
Butadiene monomers, synthetic rubbers, synthetic latex, polymerized toners, singlewalled 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 ofTokuyama 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,
to contribute to the realization of a “Sustainable Earth” and “Safe and Comfortable Life for People,” as a petrochemical plantthat 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 plantthat is 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 safetyperformance.
3. We identify all sources of danger in the workplace, and by reducing and eliminating them, we aim to achieve zerooccurrence of environmental and safety incidents and occupational accidents.
4. We strive to prevent environmental contamination, conserve energy, and reduce CO2 emissions to help protect theenvironment.
5. We strive to preemptively prevent damage from occurring and spreading by anticipating the advent of natural disasters oroutbreaks of infectious diseases
6. 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.
7. 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 motto of the Tokuyama Plant is “valuing smiles.” This means that it is vitally important for us
to have the trust of everyone in the local community. To realize this goal, we have been
implementing a policy of “safety first, no matter what,” and, striving to be a factory that isappreciated by everyone, we are continuing our efforts to become a plant characterized bystability and safety, thanks to the efforts of every employee to challenge themselves. Goingforward, we will be working to become a plant that is supported by all, by remaining rooted in thelocal community and addressing social problems such as environmental issues.
Tokuyama Plant Manager
Tomohiro Shibuya

Safety Initiatives
PolicyAchieve “zero incidents and zero accidents” through the continued implementation of a self-directed improvement cycle.
Specific Initiatives
・Firmly establish 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 substances), develop self-directed activities,
and prevent occupational accidents for everyone working at the plant.
・Prevent work environment related safety incidents by implementing continued improvement of the safety management
system and by striving to evolve risk identification.
-1-FY2022 Site Reports > Zeon Corporation – Tokuyama Plant

Environmental Impact Reductions
PolicyProceed with measures aimed at achieving our CO2 emissions reduction target by 2030.
(1) Promote the per-unit energy consumption improvement cycle and achieve the planned targets(2) Promote planning aimed at CO2 emissions reduction
Scope of Environmental Management System(1) Organizational: Departments of the Tokuyama Plant, Zeon Corporationunit
Function: Manufacturing of synthetic rubbers, synthetic latex, film materials, and carbon nanotubes, andpilot research on synthetic rubbers and thermoplastic resins
Physical: The entire area of the Tokuyama Plant, Zeon Corporation, 2-1 Nachi-cho, Shunan City,
boundary
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
servicesto customers, and responding to complaints from customers and local residents(3) Authority and: Head Office divisions (including design and development), partner companies (productcapacity oflogistics, disposal 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 striving 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 and reduce our CO2 emissions through day-to-day management
and problem identification by the Plant’s Energy Conservation Working Group and Energy Conservation Promotion
Committee, and through the examination of technological counter-measures in coordination with related company-wideprojects.
4. Reducing impacts on air quality and on water quality
・We are striving to reduce our NO x, 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
Butadiene consumption (tons)
Hazardous
substances

FY2017FY2018FY2019FY2020

FY2021

179,158

142,574

170,882

119,234

159,970

0.80.81.0

0.7

0.9

19,06016,654

18,76913,934

17,701

0.6

0.6

0.6

0.6

0.6

412,431

342,547

397,462

286,779

388,719

3.0

1.9

2.4

2.0

2.3

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

Substances
subject tothe PRTR
Act

Consumption (tons)
Emissions (tons)-2-FY2022 Site Reports > Zeon Corporation – Tokuyama Plant

Industrial
waste

Amount generated before compacting(tons)

28,89825,49623,063

18,632

26,799Amount generated after compacting(tons)

4,9325,222

4,080

3,941

4,815

0.0

0.0

0.0

0.1

0.5

Standards on the promotion of energysaving/global warming countermeasures

261,456

231,443

239,913

196,226

241,018

CO2 emissions (tons) Scope 1

239,869

214,908

239,770

194,078

246,166

CO2 emissions (tons) Scope 2

21,291

23,375

21,298

20,956

15,984CO2 emissions (tons) Scope 1+2

261,160

238,282

261,068

215,034

262,150

SOx emissions (tons)

796

689

770

579

795

NOx emissions (tons)

256

216

224

191

234

Soot emissions (tons)

7.3

3.8

6.1

3.76.0

8,705

7,852

8,063

7,854

7,862

8,206

7,457

7,576

7,747

7,626

COD emissions (tons)

52

47

61

50

53

Total phosphorus discharge (tons)

0.6

0.5

0.7

0.7

0.6

Total nitrogen discharge (tons)

26

22

30

24

36

105,323

93,430103,451

86,810104,810

92%

97%

94%

103%

93%

626,406

527,914604,514461,083

619,550

Amount sent to landfills (tons)
CO2 emissions (tons)

Atmospheri
c emissions

Water resource consumption (1,000 m3)(industrial water + groundwater + waterworks)

Total wastewater discharge (1,000 m3)
Wastewater

EnergyConsumption (crude oil equivalent, kL)
Unit consumption index (FY1990 = 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-3-FY2022 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, 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 Festival
We have held the festival since 1974 to deepen interaction with employees’ families
and community residents. Approximately 2,000 people participated this year.
・Participate in Responsible Care Council community dialogue events
We provide reports on our Responsible Care activities, including environmental improvements and safety measures, tolocal authorities and community representatives.
・Experimental classroom (making a super ball)
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
・Plant tours for junior high school and senior high school students-4-