FY 2017 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 suchas rubber gloves, cosmetic sponges, and non-woven fabric. Kawasaki Plant produces

Aerial view of Kawasaki Plant

many relatively high-value-added products in small quantities.
Environment and Safety Policy
Kawasaki Plant has defined the following environment and safety policy based on being a petrochemical plant that
handles high-pressure gas as well as hazardous and poisonous substances and is located in the Keihin IndustrialComplex.
1. With the participation of all employees, we are committed to achieving safe and reliable operations and being aplant trusted by everyone in the local community.
2. We identify all sources of danger in the workplace, and by reducing and eliminating them, aim to achieve zerooccurrences of environmental and safety accidents and occupational accidents.
3. We strive to continuously reduce environmental impacts in all work processes and prevent environmentalcontamination.
4. We comply with environment- and safety-related laws and regulations, agreements, and internally defined rules
and regulations. We also strive to maintain and improve our level of environmental and safety performance.
5. We conduct activities to prevent damage from arising as well as reduce damage from disasters in the scenario ofa major earthquake and tsunami striking the Tokyo metropolitan area.
6. We strive to maintain and improve the mental and physical health of all employees and create a vibrant andengaging workplace.
7. We set targets and conduct activities in the areas of the environment, safety, and occupational health and safety.
We aim to improve 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 inregular cleanups of the Tonomachi-Yako Route, a highway running through our area.
Our employees also plan and hold events at the plant for local companies andresidents as a way to give back to our community.
We strive to coexist in harmony with the local community to build trust and alleviate
concern.
Kawasaki Plant Manager
Takafumi Kawanaka-1-

FY 2017 CSR website

Site Reports > Zeon Corporation – Kawasaki Plant

Safety Initiatives
PolicyEnsuring safety is our highest priority, and we are committed to eliminating accidents and incidents with theinvolvement of all employees. We have been integrating companywide safety activities since FY 2016 with the goalof continuously improving our safety operations.
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 Kawasaki Plant, Zeon Corporation
Function: Manufacture of synthetic rubbers, synthetic latex, and electronic materials
Physical boundary: Total area of Kawasaki Plant, Zeon Corporation, 1-2-1 Yako, Kawasaki-ku, Kawasaki,Kanagawa, and 1-2-2 Yako, Kawasaki-ku, Kawasaki, Kanagawa, Japan(2) Organizational activities: Work processes of manufacturing from raw materials procurement, packaging, storage,and shipping, and utility operations including wastewater from the R&D Center
Products and services: Synthetic rubbers, synthetic latex, electronic materials and products, providing
information to customers, and response when complaints arise from customers and in the local community(3) Authority and capacity of managing and influencing organization: Head Office divisions (including design anddevelopment), 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.

-2-FY 2017 CSR website

Site Reports > Zeon Corporation – Kawasaki Plant

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 0.005 tons

Kawasaki Plant
Hazardous

Butadiene consumption

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

Substances

Consumption (tons)

subject toEmissions (tons)

the PRTR

FY 2012FY 2013

FY 2014

FY 2015

FY 2016

22,841

20,372

23,53421,75823,040

2.7

2.4

2.59

2.0

1.9

10,872

9,653

11,405

10,746

11,007

1311

11.2

4.9

3.5

44,70940,20345,847

43,954

43,954

25.6

26.1

27.9

21.4

19.0

50,87848,03952,90044,38056,330

5,037

4,024

4,401

3,412

4,704

0.9

0.0

0.0

0.0

0.0

Act
Industrial

Amount generated before

waste

compacting (tons)
Amount generated after
compacting (tons)
Amount sent to landfills(tons)

AtmosphericCO2 emissions (tons)

27,96820,917

25,77823,443

21,409emissions

SOx emissions (tons)

0.1

0.2

0.1

0.3

0.1

NOx emissions (tons)

87

5.7

5.6

5.9

Soot emissions (tons)

1

1

0.6

0.5

0.5

－－－

0.0

0

3,313

3,092

3,657

3,241

3,244

1,904

2,031

2,185

2,265

2,030

42

45

44

35

42

0.2

0.3

0.2

0.23

0.24

115

93

114.5

89

72

16,552

14,406

14,70013,355

12,857

Fluorocarbon leaks (tons ofCO2)
Water resource consumption (1,000 m3)(industrial water + groundwater + waterworks)

Wastewater

Total wastewater discharge(1,000 m3)
COD emissions (tons)
Total phosphorus discharge(tons)
Total nitrogen discharge(tons)

EnergyConsumption (crude oilequivalent, kL)-3-FY 2017 CSR website

Site Reports > Zeon Corporation – Kawasaki Plant

Unit consumption index

91%

75%

84%

65%

77%

82,757

73,83485,44180,22982,271(FY 1990 = 100)

Production equivalent (tons)

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

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 invite area companies and community residents to the Kawasaki Plant
Summer FestivalGroup 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.
・We hold meetings with representatives from local government together with eight
member companies of the Kawasaki district of the Japan Chemical Industries
Association Responsible Care Committee

Communication with local
government bodies

3. Plant tours
We give plant tours to introduce the plant’s production activities and initiatives.
・For community residents and groups (7 tours, a total of 61 people)
・Tours for school groups (5 schools, a total of 164 people)
Plant tours (technical school-4-students)