FY2021 Site Reports > Zeon Corporation – Mizushima Plant

Zeon Corporation – Mizushima Plant
Mizushima Plant Profile
Main Products
Isoprene rubbers, thermoplastic elastomers, petroleum resins, synthetic aromas, highperformance resins, RIM molded articles, isoprene monomers, butadiene monomers
Operations commenced in 1969. Mizushima Plant has facilities for extracting butadienemonomer from the C4 stream* and for extracting isoprene monomer from the C5 stream*,and produces various products using the C5 stream.
*C4 (GBP process), C5 (GPI process): Hydrocarbon molecules containing four and five carbon atoms,
respectively, produced as byproducts of thermal cracking of naphtha.

Aerial view of Mizushima Plant

Plant Policy by the Plant Manager
In line with the Zeon Group’s 2030 Vision of becoming “a company that lives up tosocietal expectations and the aspirations of employees,” everyone at the Mizushima Plant
is working together to realize the Plant’s Enterprise Blueprint for 2030, which is for us tobecome a “core plant that refines and hands down the frontline capabilities and technicalcapabilities that have enabled us to produce world-leading products, while also continuing
to make a positive contribution to the global environment and to society.”
This Enterprise Blueprint is based on the following approach: “The Mizushima Plant is acore factory for the Zeon Corporation that will continue to produce world-leading products
through comprehensive utilization of the C5 stream. We believe that, in the future, we cancontinue to be a plant characterized by safe, stable production by maintaining, refining andhanding down to future generations the frontline capabilities and technical capabilities ofwhich we are so proud, including the production skills and ability to respond to challenges
displayed by our staff and operatives, who have to handle a wide range of products and alarge number of production equipment for different distillation and polymerization
processes, while also strengthening our environmental technologies and costcompetitiveness, realizing plant management characterized by overall optimal efficiency,
and continuing to make a positive contribution to the global environment and to society.”
We will continue working to make the Mizushima Plant a plant that is trusted by the local
community and by society as a whole.

Corporate Officer and Mizushima Plant
Manager
Makoto Watanabe

Safety Initiatives
Safety Policy
As a world-leading plant in the comprehensive use of C5 in integrated production from raw materials to finished products, andwith a commitment to contributing to society as provided for in Zeon’s CSR Policy, and to preventing accidents and disasters
as provided for in Zeon’s Safety Philosophy, we define our safety policy involving production activities for petrochemical
products as follows.
1. Safety takes precedence over all else; we implement safety measures, identifying the sources of risk and conducting
activities to reduce the risks, and we conduct thorough safety education and training on an ongoing basis.
2. We establish a Safety Management System and are committed to accident and disaster prevention; the Safety Management
System is regularly revised and improved to enhance its effectiveness.
3. We comply with safety-related laws and regulations, independently set targets for policy issues, and strive to improve thelevel of plant safety through activities that involve participation by all employees.
4. We pursue safe and reliable production through production innovations to create a workplace in which employees can workwith peace of mind, and which earns the enduring trust of the local community.
Specific Initiatives
・Preventing past incidents and accidents from being forgotten
To keep alive the lessons learned from past incidents and accidents and prevent them from being forgotten, on theanniversary of the incident or accident, an e-mail is sent out that includes an overview of the incident or accident and detailsof the lessons learned from it-1-

FY2021 Site Reports > Zeon Corporation – Mizushima Plant

・Four-round risk assessment drills
We hold this training together with affiliate companies to improve employees’ sensitivity to and promote higher selfawareness of dangers.

Environmental Impact Reductions
Environmental Policy
As a world-leading plant in the comprehensive use of C5 in integrated production from raw materials to finished products, andwith a commitment to contributing to society as provided for in Zeon’s CSR Policy, and to preventing accidents and disasters
as provided for in Zeon’s Safety Philosophy, we define our environmental policy involving production activities forpetrochemical products as follows.
1. Based on our company mission as a social institution, we build an Environmental Management System encompassing all ofour business activities, and we are committed to conserving the environment both at the local level and on the global scale.
2. We aim to achieve zero emissions and innovative energy savings, including through improvements to manufacturing
processes using proprietary technologies and taking proactive environmental measures in new product development.
3. We comply with environment-related laws and regulations, independently set targets for policy management issues, andstrive to continuously improve the environment through activities that involve participation by all employees.
4. We pursue safe and reliable production through production innovations to be a plant that earns the enduring trust of thelocal community.
Scope of Environmental Management System(1) Name of: Mizushima Plant, Zeon Corporation
registeredorganization(2) Address: 2767-1 Kojima Shionasu Aza Niihama, Kurashiki City, Okayama Prefecture(3) Scope of: Manufacturing of synthetic resins, specialty chemicals, chemicals and synthetic rubbers
registeredactivities(4) Affiliated: Okayama Butadiene Co., Ltd. Mizushima Plant
companies
located in-plant
Scope of activities: Manufacture of butadiene monomer(5) Staff: All people who work at or for the plant
Specific Initiatives
1. Reducing emissions of hazardous chemical substances
・We have achieved zero atmospheric emissions of butadiene since FY2002 and continue to take steps to reduce ouremissions of volatile organic compounds.
2. Reducing industrial waste
・Final landfill disposal target: 5 tons or less
・We are reducing the amount of waste we generate, reusing beverage bottles, and recycling plastics as solid fuels.
3. Conserving resources and energy
・Process stabilization
・Inspecting steam traps throughout the plant
・Improving unsatisfactory areas
・Effective utilization of the energy from waste heat
4. Reducing impacts on water quality
・Strengthened management of treatment conditions (installed measurement devices in the wastewater treatment system)-2-FY2021 Site Reports > Zeon Corporation – Mizushima Plant

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

FY2016FY2017FY2018FY2019FY2020123,109106,970

122,217

93,100126,197

0.0

0.0

0.0

0.0

0.0

408,600

428,684

485,100

389,200

489,132

5.4

4.4

4.4

3.8

5.8

Amount generated before compacting(tons)

47,98045,17756,92751,56966,920

Amount generated after compacting(tons)

4,717

5,869

5,974

6,743

8,225

1.7

1.9

0.0

3.2

0.0

CO2 emissions (tons)

201,700

259,000

255,800

204,537

203,846

SOx emissions (tons)

2.2

0.1

0.4

3.8

0.0

NOx emissions (tons)

6860

73

3457

Soot emissions (tons)0.0

0.0

0.0

0.0

0.0

Water resource consumption (1,000 m3)

2,487

2,250

2,629

2,461

2,706

2,313

2,088

2,335

2,237

2,491

COD emissions (tons)

1213

1213

14

Total phosphorus discharge (tons)

0.5

0.5

0.5

0.6

0.6

Total nitrogen discharge (tons)

1212

9

8

8

Consumption (crude oil equivalent, kL)

77,626

96,576

95,830102,181

107,404

Unit consumption index (FY1990 = 100)

37%

46%

39%

50%

43%

880,300

907,200

1,052,001

874,435

1,074,436

Hazardous
substances
Substances
subject to thePRTR Act

Industrial
waste

Butadiene consumption (tons)
Butadiene emissions (tons)
Consumption (tons)
Emissions (tons)

Amount sent to landfills (tons)

Atmosphericemissions(industrial water + groundwater + waterworks)

Total wastewater discharge (1,000 m3)
Wastewater

EnergyProduction equivalent (tons)

Relationship with Employees
PolicyDevelop, cultivate and activate the capabilities of every individual employee
Specific Initiatives
・At the Mizushima Plant’s Monozukuri Training Center, we implement the basic training (covering equipment operation, safety,quality, and the various different types of production equipment) needed so that low-level operatives can contribute to thestability and safety of the plant, as well as talent cultivation (including guidance on the attitude expected from a mature adult),
for employees in their first to third years of employment.
・We are rolling out a human talent cultivation system that involves the appointment of several personnel as being responsible
for the training and cultivation of younger employees. Besides providing guidance for younger employees, these personnel
also achieve personal growth themselves from the experience of providing guidance.
・An education and training plan is formulated at the level of each individual workplace, and employees are assigned, in asystematic manner, to undergo internal level-specific training and attend external training seminars, etc.

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FY2021 Site Reports > Zeon Corporation – Mizushima Plant

Relationship with the Local Community
Thanks to the support of the local community, the Mizushima Plant marked 50 years ofoperations in July 2019.
The plant has collaborated with local communities and contributed to the development ofsociety and the region, and will continue to do so in the future.
Specific Initiatives
1. Contributing to the community through volunteering・Beautification activities in the area surrounding the plant (10 people total)
Cleanup volunteer activities

2. Interactions with the local community
・Walking for health: Around 170 family members of employees and local residents attended
the Festival
・Summer Festival: Around 550 family members of employees and local residents attended
the festival
・Participate in community events including Bon dancing and making rice cakes・Participate in Responsible Care Council community dialogue events・Lecture at Kurashiki Technical High School

Walking for health

3. Plant tours
We give plant tours to introduce the plant’s production activities and initiatives.
・Okayama Prefectural Kurashiki Technical High School・Okayama Prefectural Mizushima Technical High School・Okayama Prefectural Okayama Technical High School・Okayama Prefectural Kurashiki Minami High School, etc.
Plant tours-4-