FY 2017 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-walled carbon nanotubes
Established in 1965, Tokuyama Plant is the main Zeon production plant for synthetic
rubber using butadiene monomer extracted from naphtha. Approximately half of thesynthetic rubbers it produces are exported from the nearby Port of Tokuyama toAerial view of Tokuyama Plant

Europe, Asia, and other parts of the world. In 2015, Tokuyama Plant successfully
mass-produced single-walled carbon nanotubes, a world first.
Environment and Safety Policy
Tokuyama 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 Shunan Industrial
Complex near residential areas and railway lines.
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 set targets and conduct activities in the areas of the environment, safety, and occupational health and safety.
We aim to continuously improve our various management systems to improve our environment- andsafety-related performance.
3. 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.
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 internally defined rules
and regulations. We also strive to maintain and improve our level of environmental and safety performance.
6. We strive to maintain and improve the mental and physical health of all employees and create a vibrant andengaging workplace.

Plant Policy by the Plant Manager
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 thefoundation of everything we do,” we pursue dynamic and forward-looking plant
operations with the participation of 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.
Corporate Officer and Tokuyama
Plant Manager
Makoto Watanabe-1-

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Site Reports > Zeon Corporation – Tokuyama Plant

Safety Initiatives
PolicySafety first! Employees take responsibility for their actions to realize zero accidents and disasters.
Specific Initiatives
・We routinely implement four types of safety activities to reduce work-related risks.
・We identify the sources of hazards to prevent safety-related accidents.

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 from backsliding.
(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 Tokuyama Plant, Zeon Corporation
Function: Manufacture of synthetic rubbers, synthetic latex, film materials, and carbon nanotubes, and pilot
research on synthetic rubbers and thermoplastic resins
Physical boundary: Total area of Tokuyama Plant, Zeon Corporation, 2-1 Nachi-cho, Shunan-shi, Yamaguchi,Japan(2) Organizational activities: Work processes of manufacturing from raw materials procurement, packaging, storage,and shipping, and utility operations
Products and services: Synthetic rubbers, synthetic latex, film materials, and carbon nanotubes, providing
information to customers, 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 (companiessupplying raw materials, etc.)
Specific Initiatives
1. Reducing emissions of hazardous chemical substances
・We have installed exhaust gas purification equipment able to stably control emissions of PRTR substances.
2. Reducing industrial waste
・We have maintained a record of zero waste sent to landfills since FY 2010.
・We are reducing our industrial waste by practicing the 3R’s (Reduce, Reuse, and Recycle).
3. Conserving resources and energy
・We are making improvements on technological issues based on our mid- to long-term plan through the Energy
Conservation Working Group and the Energy Conservation Promotion Committee.
・We are focusing intensively on daily management with the goal of achieving per-unit energy consumption of 90% or-2-

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Site Reports > Zeon Corporation – Tokuyama Plant

less of the FY 1990 baseline.
・We share information with other plants through the Energy Conservation Promotion Committee.
4. Reducing impacts on air quality
・We are operating new high-efficiency boilers to steadily reduce our NOx, SOx, and CO2 emissions.
5. Reducing impacts on water quality
・We are reducing our COD and total nitrogen emissions through modifications to wastewater treatment facilities andimprovements to treatment methods.
6. Environmental Data＊”0” indicates less than 0.5 tons, and “0.0” indicates less than 0.005 tons

Tokuyama Plant
Hazardous

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

Substances

Consumption (tons)

subject to theEmissions (tons)

PRTR Act
Industrial

Amount generated before

waste

compacting (tons)
Amount generated after
compacting (tons)
Amount sent to landfills(tons)FY 2012FY 2013

FY 2014

FY 2015

FY 2016

181,275

206,710

170,327

195,538

152,247

1.2

0.8

1.1

0.7

1.6

13,60017,464

14,37916,983

13,476

0.6

0.6

0.7

0.6

0.6

391,766

453,075

397,637

422,439

347,496

2.7

2.0

2.7

2.1

2.9

16,93919,201

24,06323,16324,738

3,505

3,377

4,674

4,737

5,208

0.0

0.0

0.0

0.0

0.0

Atmospheric

CO2 emissions (tons)

239,609279,750

237,362

263,215

228,574

emissions

SOx emissions (tons)

321.5

471.0

507.0

622.2

602.9

NOx emissions (tons)

243

205

179.0

190.9

199.6

Soot emissions (tons)

6

4

2.2

10.9

4.3

－－－

3.9

273

8,788

8,927

8,393

8,812

8,703

8,288

8,165

7,785

8,051

8,148

58

49

42

57

49

0.60.70.6

0.8

0.7

2728272825

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)-3-

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EnergySite Reports > Zeon Corporation – Tokuyama Plant

Consumption (crude oil

90,648103,000

92,423

104,326

93,669

102%

99%

106%

107%

108%

487,782

573,961

477,797

531,865

475,500

equivalent, kL)
Unit consumption index(FY 1990 = 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, andmobilize the potential of employees, based on the ideal of employees “working toward ambitious goals, always
thinking things through and taking action independently, and remaining open to change.”
Specific Initiatives
・We established an education scheme that covers basic education, environmental and safety education, vocationaleducation, quality management education, obtaining qualifications, and personal development.
・We conduct education and training with clearly defined human resource goals.
・Basic operator education(1) Education at the Monozukuri Training Center at Mizushima Plant for employees in their first to third years ofemployment(2) Professional development that transfers operational skills and technical knowledge

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 jointlywith other companies that use the industrial water and forest operators
Higashikawa Cleanup Campaign

2. Interactions with the local community
・Zeon Waraku Odori Dance Festival (approximately 2,000 visitors)

We have held the festival since 1974 to deepen interaction with employees’ families and community residents.
・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 toursHeld in conjunction with Japan Responsible Care Council community dialogue events. Leaders of five residents'
associations near the plant participated in the tours (7 people total)・Summer vacation parent and child classroom (organized by the Chamber of Commerce and Industry)-4-FY 2017 CSR website

Site Reports > Zeon Corporation – Tokuyama Plant

Experimental classroom (making a super ball), plant bus tour with about 50 participants
・Plant tours for high school students-5-