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

Zeon Corporation – Kawasaki Plant
Kawasaki Plant Profile
Main Products
Synthetic rubbers, synthetic latex
Established in 1959, Kawasaki Plant was the first plant in Japan to mass-produce synthetic
rubber. It manufactures heat- and oil-resistant synthetic rubber used in automobile engine
peripheral components. Synthetic latex is used in products such as rubber gloves, cosmetic
sponges, and non-woven fabric. Kawasaki Plant produces many relatively high-value-addedproducts in small quantities.

Aerial view of Kawasaki Plant

Environment and Safety Policy
The Kawasaki 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 Keihin IndustrialZone.
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 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.
3. We strive to continuously reduce environmental impacts in all work processes and to prevent environmental contamination.
4. 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.
5. We conduct activities to prevent damage and reduce the extent of damage in the event of a major earthquake and tsunami
striking the Tokyo Metropolitan Area.
6. We strive to maintain and improve the physical and mental health of all employees, and to create a vibrant and engaging
workplace.
7. 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.

Plant Policy by the Plant Manager
Kawasaki Plant fulfills its role as a member of the local community. We participate in regularcleanups of the Tonomachi-Yako Route, a highway running through our area. Our employees
also plan and hold events at the plant for local companies and residents as a way to give backto our community. We strive to coexist in harmony with the local community to build trust andalleviate concern.

Kawasaki Plant Manager
Takafumi Kawanaka

Safety Initiatives
PolicyEnsuring safety is our highest priority, and we are committed to eliminating accidents and incidents with the involvement of allemployees. We have been integrating companywide safety activities since FY 2016 with the goal of continuously improving oursafety operations.

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Specific Initiatives
1. Safety education including accident case studies and hands-on experiential education
2. Various safety activities including reviewing and eliminating near-miss accidents

Environmental Impact Reductions
PolicyWe are working to reduce our emissions of hazardous chemical substances and waste, conserve energy, and more effectively
use resources in cooperation with other plants in our industrial complex.
Scope of Environmental Management System(1) Organizational unit: Departments of the Kawasaki Plant, Zeon CorporationFunction: Manufacturing of synthetic rubbers, synthetic latex, and electronic materials
Physical boundary: The entire area of the Kawasaki Plant, Zeon Corporation, 1-2-1 and 1-2-2 Yako, Kawasaki-ku, Kawasaki
City, Kanagawa Prefecture(2) Organizational activities: Business processes from raw materials procurement through to manufacturing, packaging, storage
and shipping, and utility operations including wastewater discharge from the R&D Center
Products and services: Synthetic rubbers, synthetic latex, electronic materials and products, 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 supplying
raw materials, etc.)
Specific Initiatives
1. Climate change-We have installed the latest gas engine cogeneration system as a way to conserve resources and energy.
-We provide a steady supply of excess electricity to external users.
-We are developing processes that effectively use steam and waste heat to continue reducing our environmental impact.
2. Reducing emissions of hazardous chemical substances
・We have installed butadiene and acrylonitrile recovery equipment.
・We are making improvements to equipment to prevent steam containing acrylonitrile from escaping from openings in
production equipment.
・We are studying technologies to reduce acrylonitrile emissions to 1 ton or less.
3. Reducing waste
・We are separating and reusing resources (recycling and heat recovery) to reduce our industrial waste.
・We are implementing steps to reduce the amount of industrial waste we generate in the first place.
4. Reducing impacts on water quality
・We are reducing nitrogen compounds in our wastewater.
・We are making technology improvements to increase stability in managing load fluctuations.
5. Environmental data＊“0” indicates less than 0.5 tons, and “0.0” indicates less than 0.05 tons

Kawasaki Plant
Hazardous
substances

FY 2014

FY 2015

FY 2016

FY 2017

FY 2018

Butadiene consumption (tons)

23,53421,75823,04021,94025,121

Butadiene emissions (tons)

2.59

2.0

1.9

2.1

2.5

11,405

10,746

11,007

10,78012,551

115

4

3

3

Acrylonitrile consumption (tons)
Acrylonitrile emissions (tons)-2-FY 2019 CSR website Site Reports > Zeon Corporation – Kawasaki Plant

Consumption (tons)

45,847

43,954

43,95444,01250,368Emissions (tons)

27.9

21.4

19.0

17.5

17.2

Amount generated before
compacting (tons)

52,90044,38056,33042,734

51,836

Amount generated after
compacting (tons)

4,401

3,412

4,704

3,293

4,198

0.0

0.0

0.0

0.0

0.0

CO2 emissions (tons)

25,77823,443

21,40923,61027,501

Atmospheric

SOX emissions (tons)

0.1

0.3

0.10.00.0emissions

NOX emissions (tons)

5.7

5.6

5.9

7.7

8.5

Soot emissions (tons)

0.6

0.5

0.5

0.6

0.6

3,657

3,241

3,244

3,143

3,467

2,185

2,265

2,030

2,029

2,272

COD emissions (tons)

4435

42

56

52

Total phosphorus discharge (tons)

0.2

0.23

0.24

0.2

0.2

Total nitrogen discharge (tons)

114.5

8972

103

110

Consumption(crude oil equivalent, kL)

14,70013,355

12,857

10,957

13,296

Unit consumption index(FY 1990 = 100)

84%

65%

77%

66%

66%

85,44180,22982,271

79,88391,394

Substances
subject to thePRTR Act

Industrial waste

Amount sent to landfills (tons)

3

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

Total wastewater discharge(1,000 m3)

Wastewater

EnergyProduction equivalent (tons)

Relationship with Employees
PolicyWe aim for employees to individually develop and improve the skills they need to perform their duties and to cultivate a spirit ofcooperation among employees as we implement systematic and ongoing development of self-reliant human resources able tothink and act autonomously.
Specific Initiatives
・Education at the Monozukuri Training Center at Mizushima Plant for employees in their first to third years of employment
・Internal group trainings
・On-the-job training and other vocational education
・Education offered by external parties
・Support for personal development-3-

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

Relationship with the Local Community
Specific Initiatives
1. Contributing to the community through volunteering
・We participate in regular cleanups of the Tonomachi-Yako Route, a highway running
through our area, together with other companies and Kawasaki City (twice/year)
・We undertake cleanup of roads that constitute commuting routes for our employees (fromKojima Shinden Station to the plant) as a self-directed activity by the plant (four times ayear)

Group cleanup

2. Interactions with the local community
・We provide business reports and give plant tours (once/year).
We hold meetings with four neighborhood associations in the community, where we
discuss our operations and other relevant topics.

Communication with local
government bodies

3. Plant tours
We give plant tours to introduce the plant’s production activities and initiatives.
・For local residents, community organizations and schools, etc. (10 tours, a total of 107people).This year, we also welcomed bus tours organized as part of the Kawasaki
International Eco-Tech Fair, and we held factory tours for local residents living in andaround Kawasaki City.
Plant tours (Kawasaki International
Eco-Tech Fair bus tour)-4-