Column

No.

14

Denka Chloroprene rubber chips

Denka chloroprene was the first special synthesized rubber to be commerweather. It is used in an array of products, such as car parts, electric cables,
wet suits, and medical gloves.
Shortly after World War II, Denka, under its new diverse policies, made its
way into the synthetic organic chemistry industry. Denka then started toresearch the development of chloroprene rubber. As commercialization was
said to be difficult, Denka twice reached out to DuPont in the US, the creators of chloroprene, to negotiate implementing their technology; however,they were unsuccessful.
“Then why don’t we produce it ourselves?” suggested Yosoichi Nomura,the Company President at the time, leading to the company’s attempt tocreate their own chloroprene rubber. They were confident the results of
their ongoing research on acrylonitrile* would help them in mass-producing
chloroprene rubber. After investing in the facilities and researchers, researchbegan at the Omi Plant in 1959. It was only three years later, in 1962, thatthey established the manufacturing technology and successfully mass-produced chloroprene rubber. Reaching their goal with such speed showed theworld just how advanced Denka’s technology was.
The product would be called “Denka Chloroprene” and would grow alongside the automobile industry. At the beginning of the year 2000, Denka
aimed to improve their productivity by enhancing their facilities. Denka is
now the world’s biggest producer of chloroprene rubber. In recent years,
it is being used in electric vehicles and the demand for it is anticipated towith its world-class facilities and the technology developed by the hard workof its predecessors.
*Acrylonitrile: An organic compound used in producing synthetic fiber. Denka has been using it since 1951,
but due to a shortage in material, they have ceased production.

Unauthorized
reproduction prohibited

continue growing. Denka hopes to keep supporting its customers' needs

Published: January 1, 2023/ Publisher: Corporate Communications Dept., Denka Co., Ltd. / Editor-in-chief: Hiroyuki Yamamoto /Nihonbashi Mitsui Tower, 2-1-1 Nihonbashi-muromachi, Chuo-ku, Tokyo 103-8338

cialized in Japan. It has excellent elasticity and is resistant to heat, oil, andWinter
2023

14

Vol.

Vol.14

Denka Chloroprene

The DenkaWay

2023

The Product of the Challenges and Efforts of ourPredecessors

The DenkaWay WinterGunbai

Semiconductors Shape the Future
Contents
2 Amazing the World with Innovation
Semiconductors Shape the Future

8 Think INNOVATION
Creating Music Starts with Creating Atmosphereby Miho Hazama, Composer/Arranger/Conductor

9 Challengers for Denka Value-Up
On the Frontline of the Threefold Value-Up

16 A Specialist’s Perspective
17 DENKA TOPICS
18 With You, With Denka.
20 Gunbai Column

Semiconductors
Shape the Future
Semiconductors were once said to be an industrial staple.
As they are now used in practically everything, they are almost as abundant as air.
However, there are likely to be some people who don’t yet know about them.
In this article, we provide a detailed overview of semiconductors and the outlook for the industry.

Amazingthewith Innovation

2

The Denka Way | 2023 WinterFirstly,
what are semiconductors?

power of semiconductors.

Flying drones delivering shipments. Robotic waiters
serving in coffee shops. Going for a walk with an avatar

that have a long history, such as diodes that transmit

robot. Driving with EVs. Thanks to automatic driving,currents in one direction and transistors that control

it is now easy to enjoy the view out the window while

the currents of electricity, are also semiconductors. In

driving. In the not-so-distant future, where we live may
well be like this. What shapes such a society, is thefunction, such as diodes and transistors, are referredcombination of memory ICs and logic ICs.

to increase, as exemplified by the electrification of

Semiconductors are substances with properties

to as discrete semiconductors. On the other hand, ICs

In the 1980s when Japan was known as a semi-

automobiles, the development of AI, and increases inthat are somewhere between conductors that conduct

package discrete semiconductors and other electronic

conductor superpower, the country was mainly man-sensor demand due to the expansion of IoT (Internet

electricity and insulators that do not. Electronic parts

devices on a single board.

ufacturing memory ICs. In recent years, logic ICs haveof Things). Semiconductors are extremely critical forbecome a hot topic due to global shortages. Logic ICs

the development of society and, ultimately, the futureis memory ICs. These assume information storage

started to be used in electronic home appliances in theof humans. Denka’s technologies and products areroles. The other is logic ICs, whose roles are in calcula-

1980s and are currently used in most products driven

making a significant contribution to the evolution ofrecent years, semiconductors are mainly ICs (Integrated

tion. For example, as the basic operation of a computer

by electricity. It is anticipated that the applications insemiconductors.

Circuits). Individual semiconductors that have a single

is to store and calculate, they are configured with awhich semiconductors play active roles will continue

ICs can mainly be categorized into two types. One

2023 Winter | The Denka Way

3

Interview with a specialist

AI

Aiming for the Top with YourBest Work in the Ever-Increasing
Demand for Semiconductors
Mr. Atsushi Osanai

Professor at Waseda Business School(Graduate School of Business and Finance)
Visiting Professor at BBT University

Profilesemiconductor business would peak as it has now.

cutting-edge technologies from becoming available

Due to the unanticipated high demand, semicon-

to China is accelerating in the US and Europe, andductor manufacturers cannot actively make invest-

this may put brakes on the growth of the entire

These days, the shortage of semiconductors often

ments in technologies from a decade ago. Demand

semiconductor industry. In addition, if the formation

comes up in conversations. There are several

is increasing, yet production is not. The supply-of economic blocs makes progress, such as the bloc

reasons for this. One reason is the hoarding of parts

demand balance is deteriorated, and therefore

involving the US, Europe and Japan and the bloc ofand components by the US and China due to theirsemiconductors are in short supply. This situation will

China and Russia, distribution will only occur withintrade conflict. Another reason is transport congestion

likely continue for a while, but in Japan, as a neweach bloc, making the until recent stable global

caused by the recent pandemic is making it difficult

semiconductor factory in Kumamoto Prefecture is

supply difficult.

to supply materials and is affecting production.

planned to start operations in late 2023, the situation

One of the biggest reasons for the shortage is the
expanding applications of semiconductors, particularly the drastic increase of semiconductors used in
automobiles. Years ago, semiconductors were notis expected to gradually improve.

Concerns about
economic bloc formations

Keywords ofsemiconductor technology

CO2
reductions
Engines and other processes that generate CO2 will
be replaced with processes using electricity, suchas motors. Semiconductors will be used to control
them. In addition to automobiles, many more things
such as ships, aircrafts, and boilers at factories will
become electric.

Communication

He was engaged in product planning, technological planning, etc. at SONY for ten years. After being
named general manager of the Product Strategy Division, he studied at Kyoto University’s Graduate
School on a business assignment. After earning a doctorate degree, he served as associate professor
at Kobe University, an external advisor to SONY Corporation, etc. before becoming an associate professor at Waseda University in 2011. He was assigned to his current position in 2016. He also serves
as a researcher at Harvard University and as an advisor to both Japanese and overseas companies.

Increased use inautomobiles continues

5G technology has spread widely anddevelopment of 6G is making progress. It
is necessary to process and transfer larger
data at a higher speed than ever before,
but radio-waves and optical fibers havephysical limitations. It is therefore expectedthat needs for semiconductors with higher
performance capabilities will increase.

Amazingthewith Innovation

it created. Even when something new is created, if it

second place. Most of the top ten companies arework we are the best at.” When considering eco-does not immediately sell, they immediately move on

either Chinese or Korean. The same can be said of

nomic performance, it is important to keep in mind

technologies were clearly divided for military andto the next new thing in an attempt to recover.

solar panels and large LCD panels. Despite being

the words “the best.” Individual Japanese companies

civilian applications. However, as commercial drones

The semiconductor industry is a processdeveloped in Japan, Japan does not get to reap

need to discover their “best” and create new values.

are being utilized as weapons in the Russian invasionindustry. Through mass production, it can reducethe benefits of these technologies. Those enjoying

They can’t just stop at creation though. It is importantof Ukraine, such barriers have been removed. Givencosts, and give a competitive edge. It is an industry

the benefits are Chinese, Korean, and Taiwanesethat they actually profit from these values.

that cannot succeed without pursuing quantity.

companies. We must change this structure. The

Conventionally, cutting-edge semiconductor

Denka must also earn value out of the technolo-

employed in automobiles. With a wider and more

Looking forward, it is unlikely that semiconductor

this situation and looking from the perspective of

popular application of ECUs (Electronic Control Units)demand will decrease. Demand from the automobile

security, it is possible that semiconductors might not

One of the internationally competitive products

determination to not only just invent things but also

gies it has created. The company is also required toto control engines, transmissions, power steering, etc.

industry continues to be strong. Thanks to the devel-

be distributed as before. Having said that, even if thebeing created in Japan is SONY’s image sensor. Why

establish a system to earn profits and maintain awork with customers and other manufacturers andin automobiles, the number of semiconductors used

opment of automatic driving technology and electric

formation of economic blocs progresses, semicon-

are they competitive? The reason is that SONY hasleading position is required for both Japan andbuild strategies to assure that final products lead toJapanese companies.

actual business.

has also increased. Now, it is not all that rare to use

cars, the number of semiconductors employed will

ductor demand will likely continue to grow withina leading share. Becoming a second or third-rate

more than 100 semiconductors in a single car.

increase even more.

each bloc.

player would put them at risk of becoming trapped

In addition to automobiles, the range of applica-

in a vicious circle where it is not possible to reduce

automobiles are not necessarily cutting-edge types.

tions for semiconductors will surely increase. Things

costs because they cannot mass produce, causing

The interior of an automobile is a harsh environmentthat use engines, such as aircrafts and ships, andwith high temperatures and humidity in addition tofactory boilers have been mechanically controlled until

Japan was once known as a semiconductor super-

severe vibrations. As a result, parts and components

now. However, a trend in reducing CO2 emissions will

power. Now, however, it is far behind other countries

that have long been used and are already known

likely lead to the use of motors and other electricalsuch as Taiwan, South Korea, and China. Japan is

To tell the truth, the semiconductors used in

Only the best can survive

Be the flag waver forJapanese companies

formation of economic blocs, the free trade system isunstable in a way which has never been seen before.

market share.

materials, whether they are organic or inorganic.

Japanese companies must have the corporate

Taking advantage of its background as a generalstrength to overcome any type of business condition.

Denka manufactures. Dr. Akira Yoshino of Asahi

chemical manufacturer, it has enhanced its techno-

The power of business needs to be enhanced acrosslogical strengths while maintaining a production

Japan, and I expect Denka to set the trend of thetimes for this.

One example is the lithium-ion battery materials

controls. For this, semiconductors will be needed.

said to be good at value creation but not at value

in a process that is about ten years old. As the

A potential cause for the slowdown of theacquisition. Even if something new is created in

was invented in Japan. Looking at current market

system to respond to demand, which has led to its

production system was built based on demand

growth of the industry can likely be attributed to theJapan, it’s left at the creation stage. Japan is often

shares, the leader is a Chinese company. Panasonic,

sense of presence in the industry.

unable to reach a point to make profits out of what

who enjoyed the number-one share, is now in

The Denka Way | 2023 Wintertions in international society and the accompanying

Denka is a company that has produced excellent

to be stable are employed. They are manufactured

formation of economic blocs. A movement to prevent

We now live in a world where, due to confronta-

their products to sell poorly and further reducing their

Kasei won a Novel Prize for this technology that

forecasts at that time, it wasn’t predicted that the4

Semiconductor chips play a majorrole in the AI process of learning frominformation and making decisions fromlearned data. The range of applications
for AI is anticipated to expand further
to, for example, handling inquiries fromconsumers and the automatic operations of automobiles and machines.

Mr. Imai, President of Denka, often mentions “the2023 Winter | The Denka Way

5

Denka’s Semiconductor Production Support ing Technologies

Spherical alumina
Spherical silica

Semiconductor manufacturing processes are evolving daily with cutting-edge technologies being introduced in succession.

Spherical silica/Spherical alumina/
Spherical magnesia

Denka’s technologies and products play pivotal roles leading up to the completed semiconductors.

Monosilane gas

Emitter(dichlorosilane, hexachlorodisilane)

Creating circuit patterns with electronic
wires only a few micrometers thick

Providing function byforming a film on wafers

Heat and shock protection
A filler is a substance that is mixed in order to give functionality to resins. Their functionality is diverse, and it includes
the improvement of thermal conductivity, controls of electrical and mechanical properties, and the improvementof workability. Semiconductor chips emit heat when operated. To enable them to operate stably, it is necessary to

An emitter is a small part that is constituted of metals

inspection equipment and other equipment used in inspec-

reduce thermal expansion differences between semiconductors and encapsulation resins or to release the heat,

A gas that forms conductive and insulating films on

and ceramics and emits electrons. With miniaturization

tion processes. In the lithography process, by irradiating

and spherical fillers that have thermal conductivity are used as sealing materials for semiconductor chips. In 1971,

wafers when a circuit pattern is formed. This gas isand microminiaturization of semiconductors in progress,

electron beams, circuit patterns are printed on glass sheets.

Denka started to manufacture Denka Spherical Silica, a semiconductor encapsulation material. Thanks to the tech-difficult to handle due to its self-ignition properties, but

situations where electron beams are required have been in-

At one time the optical lithography combining optical lenses

nology used to produce spheres from molten material at high temperatures, we can produce nearly perfect spheres

Denal Silane, a joint venture of Denka and Air Liquide

creasing, thereby increasing the employment of emitters inand ultraviolet rays was the mainstream, but electron beamwith different diameters, ranging from large to small, and combine them in an optimum manner. We have developed

Japan, has the technologies to safely mass produce it.

a wide variety of equipment, especially in wafer and mask

lithography can print finer and more complicated patterns.

many types of fillers from spherical silica, such as spherical alumina and spherical magnesia.

Front-end process Create an LSI (Large Scale Integration) by aligning several hundred semiconductors on a wafer made from silicone
Create an oxidized
film for insulationon the wafer

Manufacturing
semiconductors

Add various films
using gases forsemiconductors

Irradiate electron beams andlight on photoresists to printcircuit patterns on the wafer

Form a thin-film pattern by usingchemical reactions of chemicalsolutions, reactant gases, and ionsControl electrical properties
by injecting ions into the wafer

Post-process Cut out LSIs on the wafer for packaging

Embed metals for electrodewiring into wafer

Ion

Wafer

Thin film layer

Oxidization

Deposition

Attach tapes and fixing agents to protect
the wafer’s surface and to fix the wafer
onto the supporting substrate

Lithography

Etching

Ion injection

WiringShave the wafer
to make it thinner

Cut the semiconductor
chips formed on the wafer
Encapsulation material
created by the resin
filled with filler

Tape/Temporary
fixing material

Wafter thinning

DicingAssembly

Packing

Repeat the process

Back grinding tapes

Dicing tapes

Effective even underharsh conditions

Supporting the smooth
cutting of chips

day, with new methods being developed in quick succession. At theThis tape is used to protect the surface of wafers and to attach them toThis is a tape used to stabilize wafers during thesame time, we are receiving many requests from customers. Thanks

equipment while being grinded. Back grinding tape is frequently

dicing process (the process of cutting and sepa-

used independently, but when wafers are exposed

rating integrated circuits formed on the wafer toto severe conditions like gas, heat, andmake individual chips). It has excellent adhesion

Continue to test the limits of our material
development technologies
The manufacturing process of semiconductors is evolving day byto the material development technologies it has cultivated up to thepresent day, Denka has created materials to meet the customers’

Takuya Okada

Deputy General Manager
Electronics & Innovative
Products

chemical solutions in the front process, aand prevents the dispersion of chips while also

Sheets for carrier tapes / Top cover tapecomplicated conditions, such as semiconductors that have both

temporary fixing agent may also be usedmaking the chips easy to pull out.

heat resistant and adhesive properties, but they want the adhesive

to fix the wafers to supporting substrates.

Preventing defects

needs. Their requests are not necessarily simple. We need to satisfy

properties to disappear after being exposed to light. We need to take full advantage of the technolo-

New semiconductor manufacturing

A problem at the time of shipment is static electricity and the defects

gies we have, continue to make customer proposals, and work to improve our current technologies.

processes are created every day, and therefore

and the mix with or attachment to foreign articles that results from it. To

We want to be the company that semiconductor manufacturers and manufacturers of semicon-

6require suitable tapes and fixing agents. Taking advantage ofprevent this, semiconductor parts are protected by carrier tapes or top

ductor manufacturing equipment want to contact when in need. To become such a company, we will

the material design technologies it has cultivated and based on an analysis

cover tapes when shipped. Denka contributes to the stable supply ofcontinue to tackle new challenges and offer products that meet the needs of our customers and society.

on the molecular structure level, Denka is capable of offering products withsemiconductor parts with complete support from raw material combina-

the required properties.

tion to development and mass production of sheets and films.

The Denka Way | 2023 Winter2023 Winter | The Denka Way

7

Think INNOVATION
Introducing articles that provide hints for innovation

No. 14Creating Music Starts with Creating Atmosphere
Composer/Arranger/Conductor

Miho Hazama©Agnete Schlichtkrull

Miho Hazama has composed and arranged music for Yosuke Yamashita, Ryuichi Sakamoto, and the NHK Symphony Orchestra. In 2019, she was selected as one of Newsweek
Japan’s “Top 100 Respected Japanese People Around the World.” Her third album, “Dancer in Nowhere,” was chosen as one of New York Times’ Best Jazz Albums of 2019 and wasnominated for a Grammy Award. She has also worked as Siena Wind Orchestra’s Composer in Residence since 2017 and as The Danish Radio Big Band’s chief conductor since 2019.
In 2020, she was appointed as the permanent guest conductor of the Netherlands’ famous Metropole Orkest.

The path I discovered in New YorkCreating a motivating environment for all

I was in the second grade. The NHK Taiga Drama’s theme song moved

I have been blessed with the opportunity to work in many countries,

me and instilled in me a dream to compose orchestral music. Before

including the US, Denmark, the Netherlands, and Japan. I am always

that, I had started learning to play the electric organ and piano and wastrying to interact with people of different countries by matching theirstudying composition. After entering college, I double majored in clas-

tempo. For example, in New York people talk quickly and logicallysical and commercial composition, but I was studying in a time when

and they desire quick answers. In order to keep up, I need to kick mythe popularity of visual music was on the rise. I had always dreamed ofbrain into high gear. If I was to talk to Europeans in the same manner,

creating orchestral music, and when I wasn’t able to do that, I was dis-

they would ask me what the hurry was. In Japan, they would take me

appointed and felt like giving up on my dream.

for someone egocentric. I make a conscious effort to make sure, nomatter what country I’m in, that

During this time, I had also

I blend in.

started playing piano for the Big
Band Jazz Club and had comeIn the same way, I think

to think that maybe I should

it’s important to adjust to thefollow a path in the genre of

atmosphere of the performers

music I was enjoying there. Withand interact with them in a way

my mind made up, I decided

that suits them best. I get toto pursue a Master of Music inwork with many musicians,

jazz composition abroad at the

but we often only have a short

Manhattan School of Music.

prep time before the perfor-

After finally starting my studies,

mance. It is required that I be

I realized I was the only one inable to assess their strengths

my class without a bachelor’s

and personalities in an instant.

in jazz. I was off to a very slow

I prepare myself so that I canquestioning what I could do, but
I soon found myself thinking,of the Threefold

Value-UpNo.

05

Omuta Plant

In this segment, we focus on the worksites that are striving to realize
the threefold growth vision “Denka Value-Up.”
In this fifth edition, we will introduce the Omuta Plant.

help the band or artist put on

start. There was also a language
barrier and I often found myself

On the Frontline

Miho Hazama conducting her production of “Tokyo Jazz 2022 Neo-Symphonic! Cinema Jazz.”(August 19, 2022, Tokyo Metropolitan Theatre Concert Hall)©2/FaithCompany

the best show they can. The
performer’s personality often
shows in their music. An easy-“What if I use my classical roots, knowledge, and sense to compose or-going person’s music will sound easygoing, and an angry person’schestral jazz music?” When people think of composing jazz, what oftenmusic will sound angry. The best thing I can do for them is create acomes to mind is a big band with a horn section and a rhythm section.

space in which everyone can feel motivated yet challenged. If I can

There isn’t much jazz music written for orchestras. However, the things

manage that, I’m confident we can create great music.

I had learned, the things I wanted to do, and the motivation in New York
all led me to orchestral jazz music. I knew this would be my new identity.
8

The Denka Way | 2023 Winter2023 Winter | The Denka Way

9

Denka Evolves with
the Omuta Plant
In this section, we look back on the Omuta Plant’s 106-year history,
during which it has supported Japan’s industries and continuously
developed new technologies. Inheriting this history,
the plant will move on to the next stage.

1956

Spherical alumina was developed

Alumina cement is a
refractory material developedwith the Omuta Plant’s
electric furnace and cement
manufacturing technologies.
It is mainly used in blast
furnaces at steel mills, andDenka boasts the largest
market share in Japan.

with the high-temperature fusion

1974

1916

1975

Integrated drainage systemcompleted

1977

Manufacturing of BN
Composite EC started

Manufacturing ofacetylene black started

1943

Omuta Plant began manufacturing inorganic chemical

Manufacturing of acetylene black began inproducts such as carbides and nitrogenous lime fer-

1943, and it has become one of Denka’stilizers. Through the cultivation of inorganic chemistry

main products, used in a variety of appli-

and nitriding technologies, the foundations were laidcations including battery materials, rubber

for Denka’s development.

fillers, and electronic components.

1966
1967

1970

The Omuta Plant continues
to grow by linking the technologies of its predecessors
to future growth
The Omuta Plant began operations in 1916 asDenka’s first manufacturing site. After receiving theland from Mitsui Mining Co., Ltd., Denka chose to10

The Denka Way | 2023 Winter1992

Manufacturing of calcium
cyanamide drift less typestartedManufacturing of boron
carbide started
Manufacturing of
calcium cyanamide
granular type and
FIRELEN started

resins and rubbers.

Manufacturing of sphericalalumina filler started

1968

Denka began manufacturing AN Plate, a ceramic
circuit board with high thermal conductivity. In thesame year, the company also began manufacturing

Manufacturing of
spherical silica started

A new 40-meter high lime kiln that was

Flux Compound, which contributes to improving
the functionality of concrete.

Omuta Innovation Hub completedcompletely novel at the time. It ceased operation in 2020 with the termination of theThis is an amorphous silica

plant’s carbide business and was dismantledwith a remarkably low coeffi-and completely removed in April 2022. It

cient of thermal expansion andcontributed to stable supply and operations

excellent electrical properties

for a long time and was a symbol of theand stability. It is used as a

Omuta Plant.

semiconductor encapsulant

2004
1985

and as a resin filler in 5G
high speed communication
substrates.

1989

Manufacturing of Flux
Compound started

2009

Manufacturing of sphericalfused silica filler started

Manufacturing of Sulfex
and β silicon nitride
startedconstruct a plant there as it was possible to procure
important raw materials such as coke, sulfuric acid,and electric power at competitive prices. As partof the Mitsui Mining’s coal complex, Denka started
manufacturing inorganic chemical products such as
carbides and nitrogenous lime fertilizers. After WorldWar II, the plant grew due to an expansion of theacetylene black business. Despite concerns about
the hollowing-out of the industry due to production
being discontinued or transferred overseas, it steadi-

and improve the surface hardness of

Manufacturing ofspecial cement additives started
Manufacturing of AN Plate started

Beckenbach type
Lime kiln completed

1965

2002

can provide high thermal conductivity

1971

Manufacturing of alumina
cement started

Factory constructed andmanufacturing of calcium carbide andcalcium cyanamide started

technology cultivated in fused silica. It

Manufacturing of boron nitride
startedly improved upon its high temperature processing
and nitriding reaction technologies. Currently, itoffers a number of specialty products, including
those essential for semiconductors, xEVs. And 5G.
In 2020, a new general office called the Omuta
Innovation Hub was completed. The plant continues
to invest in new facilities for future growth and aims
to realize a decarbonized society.

Manufacturing of
ALSINK started
Manufacturing of
ALONBRIGHT
started

2020

This is a general office that brings together
the previously dispersed manufacturing,
research, and production technology
divisions. While achieving a sense of unityand functional operation as the core of theplant, it has adopted an innovative layout tofacilitate communication.

Heading into the futurewith our inherited DNA

Yoshimi Ishizuka
Omuta Plant Manager/
Managing Director

Omuta Plant has a long history of establishing proprietaryequipment and technologies, including electric furnace andnitriding technologies, some of which are found nowhere
else in the world. This history has been built up by “people.”
This plant has inherited the DNA of people who think outside the box and strive for improvement. Currently, we aretaking on new challenges, such as implementation of AI and
automation of operations. In addition, in order to contributeto the company’s goal of achieving carbon neutrality by
2050, we are considering initiatives such as converting tocarbon neutral fuel sources and purchasing electricity with
non-fossil certificates. We are also responsible for the stablesupply of environmentally friendly products, including thosefor xEVs.
In 2020, the plant ended its carbide production, which
had continued for more than 100 years. It is now upgrading
its equipment to meet the needs of new technologies suchas 5G and xEV. It can be said that we are truly in the periodof change. Cherishing our history and DNA, we will continue
to move forward into the future.
2023 Winter | The Denka Way

11

D

enka SN Plate and Denka AN Plate areceramic circuit boards with excellent thermal
conductivity. They are used as heat-dissipating
substrates for power modules in automobiles(mainly xEVs), electric trains, machine tools, andwind power generation. Along with the evolutionof semiconductor chip capabilities, dissipating
chip heat is becoming increasingly important, andthe need for both products is growing. To meetthis need, the Omuta Plant is in the process of expanding and upgrading its manufacturing facilities.
Since existing manufacturing methods require too
many employees, the plant is undergoing major
process reforms, including automation. Thesefacility expansions will be done in phases, with
future demand in mind. “We want to make theplant capable of meeting customer needs in every
aspect, including quality, production capacity, andcost,” General Manager Iwamoto emphasizes.
In addition to these two products, the Omu-Business

Value-Up

Ultrafine Powder
Experimental Building

12

The Denka Way | 2023 Winter

Staying ahead of fast-changing
industry trends
By offering BNR in addition to SN Plate and AN Plate, Denka
will become able to meet customer needs as an all-rounderin heat-dissipating substrates. We aim to be the first company
our customers rely on by developing technologies that anticipate module trends and changing demands. We hope tocontribute to the development of the semiconductor industry,
which is realizing higher and higher performance.

Yoshitaka Taniguchi

Go Iwamoto

General Manager
Ceramics Research Dept.
Omuta Plant

General Manager
Production Dept. 3
Omuta Plant

Value-Up

Upgrading Facilities for Manufacturing ofHigh Performance Spherical Fillers

Supporting the evolution of industry

Spherification Facility

by increasing production capacity and developing new products
Its thermal conductivity is 1.5 times higher thanthat of spherical alumina, enabling it to meet thegrowing need for heat-dissipating materials. The
main characteristics of Denka’s products are
perfectly spherical shapes and consistent particle
sizes, which is something that no other company
can imitate. In combination with resin, thesetwo characteristics allow for more sphericalmagnesia filler to be added, making it easier toachieve the desired functionality. Although othermanufacturers also provide spherical magnesia
for the market, none are as high performing andreliable as Denka’s products.
In 2021, our spherical magnesia won an
excellence award at the Semiconductor of theYear 2021 awards held by Electronic Device Industry News. (Sangyo Times, Inc.) Mr.
Kunitomo commented, “We have reaffirmed that
our materials technology can create new value.
Encouraged by this award, we will continue toprovide products that can meet the needs ofsociety.”

VOICE

Toward Expansion of Heat-Dissipating Substrate
Manufacturing Facilities and Launch of New Products

Imagining the future of manufacturing
As semiconductors in the marketplace continue to achieve
higher performance, technologies for improving thermal
conductivity and heat dissipation have become essential. Our
products can meet such needs. Dissipating heat and increasing the functional efficiency of devices leads to lower power
consumption and reduced environmental impact. Therefore,
to contribute to society through high performance products,
we are carrying out upgrades to realize a next-generation
plant. We will make this plant our flagship and then deploy
these upgrades at other locations throughout the company.

10,000(Thousand cars)

Bare Substrate Plant No.3

8,000
6,000
4,000
2,000
0

2018

2019

2020

Semiconductor chip

SolderOsamu Kunitomo Naoto Hayashi

Manager
Production Dept. 4
Omuta Plant

General Manager
Production Dept. 4
Omuta Plant

Manager
Production Dept. 4
Omuta Plant

2021

2022

2025

An example of modules using BNR

General power module

Shuji Sasaki

Developing BNR

Market trend of automotive power modules
Estimated electric vehicle (EV) sales

T

VOICE

Denka AN Plate

Business

Winning “Semiconductor of the Year 2021” Award by responding to market needs

he Omuta Plant is undergoing construction
at a rapid pace to expand its next-generation
high-performance spherical filler production line.
This upgrade is based on the strategic investmentof 5 billion yen announced in October 2021.
Spherical silica has a low coefficient of thermal
expansion, making it ideal for semiconductor
encapsulation materials and package substrates,
while spherical alumina has high thermal conductivity and is widely used as a heat-dissipating
material in automobiles and telecommunications.
The construction is scheduled for completion in
FY2024, with the aim of meeting the increasing
demand for high-speed large-capacity data
communications (5G) and electric vehicles (xEVs).
Because spherical fillers require a complex
manufacturing process, the plant previously reliedon manual labor and the expertise of veteranemployees. However, this facility expansion marksa shift to mechanization and automation, which
will improve efficiency and stabilize quality.
Among Denka’s spherical fillers, sphericalmagnesia offers particularly high performance.

ta Plant is developing a new heat-dissipating
substrate: BNR (BN resin complex). This productcombines the boron nitride sintering technology
developed at the Omuta Plant with the resin
mixing and composition technology of the Denka
Innovation Center and the Shibukawa Plant. It ischaracterized by high thermal conductivity, three
to four times higher than that of resin substrates
with fillers. Also, unlike ceramic circuit boards, it
can be attached directly to metal, eliminating theneed for greasing and soldering. This allows formore compact modules with better heat dissipation while reducing processes and costs. “We
are currently conducting performance evaluationsin anticipation of customer adoption,” explains
General Manager Taniguchi. “We are working
on development to achieve performance thatsatisfies our customers and aiming to establish
the technology to start mass-production as soon
as possible.”Cu substrate
Brazing material
Ceramics
Cu substrate

Baseboard・Attaching Cu substrates on both sides ofceramics using brazing material

Semiconductor chipCu substrate
BNR
Baseboard
Solder・A BNR and baseboard are
attached directly

・A ceramic circuit board and baseboard
are soldered together

2023 Winter | The Denka Way

13

T

Environment

Value-Up

Methanation process to convert exhaust gas into fuelUsed as fuelExhaust gas

Manufacturing plant

MethaneElectricity fromrenewable energy

CO2

H2

CO2 recovery unit

Hydrogen recovery unit

Hydrogen generator

CO2

H2

H2

H2O

Methanation equipment

he Omuta Plant is currently focusing on
mid-career hiring, and personnel with avariety of career backgrounds are actively
working at the plant. One such person is Mr.
Asayama, who joined the company in 2010. He
decided to change jobs after becoming interested
in Denka’s manufacturing and products. He wasworking in a completely different industry before,
but now he is involved in the manufacturing of
spherical silica.
The Omuta Plant provides a worker-friendly
environment for employees with no specialized
knowledge. Mr. Asayama attributes this in partto the standardization of work: Internal rules andwork procedures are clearly defined down to
the smallest detail. “At first, I didn’t even know
how to use the tools. But there were detailed
manuals for each task, and my senior colleagues
were kind enough to teach me, so it was easy tolearn new things,” he recalls.

In particular, he praises the open atmosphere. In the Manufacturing Dept.4, to which
he belongs, meetings are held regularly to shareinsights and discuss ways to improve operations
together with staff from partner companies.
Regardless of company and career, everyone
shares their opinions, and if they have a good
idea, they actively implement it. Diversity inhuman resources also has a positive impact
on the workplace. Mr. Asayama says, “Manyof them are highly motivated and have theirown opinions, so every meeting is very active.
Having people from different backgrounds voice
their opinions helps improve product quality andreduce workplace accidents.” He also enjoys
chatting with his supervisors and openly discusses
any problems he has. A work environment thatfacilitates communication allows mid-careerhires to shine.

VOICE

Aiming to manufacture higher
quality products
The spherical silica I am involved in manufacturing is used in semiconductors, theshortage of which is attracting worldwide
attention. We receive various requests from
customers and continue pursuing quality.
I feel a sense of accomplishment whencustomers are satisfied with our products
as a result. To ensure a stable supply ofhigh-quality products, I would like us to continue working to improve quality and optimize
operations throughout the department.

Yuichi Asayama
Silica Manufacturing Sec.
Manufacturing Dept.4
Omuta Plant

An open workplace where diverse members shine

Mid-Career Hires Enjoy Their Jobs

Aiming to achieve carbon neutrality by 2050

Fuel Conversion from LPG to LNG

L

iquefied Natural Gas (LNG) is an energy
source that emits less CO2 than Liquefied
Petroleum Gas (LPG) and can be supplied stably.
At the Omuta Plant, a project is underway toconvert the fuel for the fusion process of sphericalsilica and spherical alumina from LPG to LNG.
The production of these two products requires
the raw materials to be fused with a burner, inwhich LPG is used. About 70 to 80% of the CO2
emitted from the plant comes from this process.
On the other hand, LNG emits less CO2 thanpetroleum, so replacing LPG with LNG can effectively reduce CO2 emissions. However, this is notan easy task. Burners vary in shape, heating time,
and temperature depending on the customer’s
requirements. Since LNG generates less heat thanLPG, simply replacing the two will not produce
the same product. The Omuta Plant is looking
into ways of establishing this technology by 2030
using simulation technology and learning from theTuas Plant in Singapore, which produces the same

14

The Denka Way | 2023 Winterproducts. Once the technology is established, it
will be possible to recycle CO2 within the plant
through methanation, which recovers CO2 fromexhaust gas and synthesizes it into a natural gas
raw materials.
In addition, the plant is also working to recycle
various wastes generated in the manufacturing
process into resources. In fact, waste in the spherical silica manufacturing process is used in the
production of special cement additives.
Denka’s spherical silica and spherical alumina
have been recognized for their high performanceand maintain the number-one share in the global
market. “We will focus not only on the performance of our products, but also on reducing
environmental impact. We want to move aheadof the curve,” says Deputy Manager Kawai. All
members of the Omuta Plant are working together
to pursue high-quality products with low environmental impact, with the goal of achieving carbon
neutrality by 2050.

VOICE

Employees suggest ideas
more and more proactively
Since Denka’s Environment Value-Up wasestablished in 2021, the plant manager andHuman Resources

Value-UpI have been communicating its importanceto our employees. They are now moreenvironmentally conscious and proactively
suggest things like, “Wouldn’t this be effective in reducing our environmental impact?”
Reducing environmental impact is essential
for our customers to choose us and for the
future of society. We will continue to work on
this while actively incorporating cutting-edge
technologies.

Masahiro Kawai
Deputy Manager
Omuta Plant

2023 Winter | The Denka Way

15

DENKA TOPICS
A Specialist’s
Perspective

Introducing Denka Group news topics from October to November 2022.

Nov.

Announcement of New Vision and Next Management Plan “Mission 2030”

Denka is striving to become a

The new vision andMission 2030 can beviewed on a special
webpage.

On November 8, Denka announced its new vision and next management plan “Mission 2030,” which will
cover the period from FY2023 to FY2030 (eight years). This plan seeks to increase the value of our humanresources and management and create business value that combines the three elements of specialty, megatrends, and sustainability, with a focus on both financial and non-financial aspects of the business.
When formulating Mission 2030, Denka analyzed future indicators to clarify its raison d’etre from along-term perspective and identified three megatrends that will create business opportunities: ICT & Energy,
Healthcare, and Sustainable Living. The new vision is based on this discussion, the candid opinions of younger
employees, and the thoughts of the management team. To achieve the mission set forth in the vision, Mission
2030 promotes value creation in the three areas of business, human resources, and management to increase
corporate value.

Specialty-Fusion Company.
What do Denka’s specialists foresee
for the future?

I Want to Play a Supporting Rolein Society and in the Workplace.
Denka’s spherical silica, which accounts forabout 30% of the global market share, is used
as a semiconductor encapsulating material.
Although it is not a product that we usually see,
it is an indispensable material for semiconductors, and thus supports our daily lives.
Mr. Uno, who is in charge of the spherical silica
production process, also handles the training of
on-site staff. That is because skills improvement
and multi-skill development is essential forstable production. Mr. Uno actively communicates with everyone on site, from experienced
staff to new hires and temporary workers. He
explains, “The quality level demanded by ourcustomers is increasing, especially for semiconductor materials used in automobiles. Our

Oct.

Silicon nitride production capacity for xEVs
to be increased by 1.5 Times

Aiming for further growth in the environmental and energy fields, Denka has decided
to make a new capital investment in silicon
nitride at its Omuta Plant, an additional
1.5-fold increase in production starting in
2023. This product has been well-received in
automotive applications, where performancerequirements are severe, and with the expansion of the xEV market, demand is
rapidly increasing for use in heat-dissipating substrates for inverters.

Oct.

Strategic investment of approx. 2.3 billion yen
in Toyo Drain polyethylene drainpipes

Denka has decided to make a strategic investment ofapproximately 2.3 billion yen in Toyo Drain polyethylene drainpipes manufactured by Kyusyu Plastic
Industry Co., Ltd., one of Denka’s subsidiaries, toacquire land, relocate manufacturing facilities, andinstall new equipment. This investment will increase
our supply capacity for this product, which is increasingly being used for collecting and draining groundwater in infrastructure development.

goal is to provide products of the highest quality
by making maximum use of our workplace
experience and knowledge.” He is committed

Oct.

to further raising the quality level to meet theincreasing standards. “I would like to take fulladvantage of our technological capabilities andpay sufficient attention to quality control, so that
our customers will say, ‘We couldn’t have done
it without Denka’s spherical silica.’”Nobuyuki Uno

ManagerFine Section, Silica Production Section,
Manufacturing Dept. 4
Omuta Plant
Joined the company in 1992. He is responsible for the
production process of silica products of less than one
micrometer and special products that are highly customized to meet customer requirements.

16

The Denka Way | 2023 WinterDenka and SCGC agree to establish a joint venture
for the production and sale of acetylene black

Denka has entered into an agreement withSCG Chemicals, a leading Asian conglomerate, to establish a joint venture company to
manufacture and sell acetylene black. Denka
was planning to establish a new manufacturing facility as a measure to meet the rapidly
increasing demand. Following the establishment of the joint venture, a new facility withan annual production capacity of approximately 11,000 tons will be established.

Oct.

Portfolio reforms through withdrawal from cement business andrestructuring of carbide chain

Oct.

Naming rights sponsorship contract with Denka
Big Swan renewed

Denka, Niigata Prefecture, andAlbirex Niigata have decided torenew the naming rights agreement for Denka Big Swan Stadium.
A joint press conference was heldat the stadium on October 23. The
stadium is the home ground of
Albirex Niigata, which has returnedto the J1 League after a six-year absence.

Denka has agreed to transfer all shares of its cement business to a new wholly owned subsidiary by the endof March 2023 through an absorption-type company split, and then transfer all shares of the subsidiary to
Taiheiyo Cement Corporation. Denka has resolved to terminate cement production by around the first half of2025 and to withdraw completely from in-house limestone mining and cement manufacturing operations.

2023 Winter | The Denka Way

17

With You, With Denka.

We interviewed three people who were in involved in renewing the contract.

We want to liven up Niigata Prefecture
through the power of sports!

With Society.

From left: Toshio Imai, President of Denka, Hideyo Hanazumi, Governor of Niigata Prefecture, and Yukio Nakano, President of Albirex Niigata

Tamagawa: First of all, I am very happy that

Tamagawa: I’m really looking forward to seeing

we were able to successfully renew the con-Albirex Niigata playing in the J1 League at

tract. We have two sites in Niigata Prefecture,

Denka Big Swan Stadium this year. I am sureand about 2,000 people, or one third of our

the supporters will be very excited as well.

employees, work there. We hope that this agree-

Inazuki: Niigata Prefecture hopes that thement will help the people of Niigata Prefecture

Niigata Sports Park, which includes this sta-

become even more familiar with our company.

dium, will attract people of all ages as a mecca

Inazuki: When we announced the renewal offor sports. As we consider new ways of using

the naming rights agreement, we received com-this system, we would like to draw on thements of gratitude from prefectural residents.

insights of Denka, which is involved in a variety

I think this is because the name “Denka Bigof activities that contribute to the community.

Swan Stadium” is already well established in theKurashina: Albirex Niigata hopes to provide

prefecture.

inspiration and courage to spectators throughKurashina: This stadium is a symbol of Niigata

soccer. Denka is involved in various activities

Prefecture, and as our home stadium, it is a

to contribute to the community through thespecial place for Albirex Niigata. Denka is also

stadium, and we hope it will continue its efforts

a uniform partner for our team, and we are

to promote sports while keeping an eye on thehonored to continue working with you. Albirex

COVID-19 situation.

Niigata won the J2 League championship andTamagawa: I am looking forward to working

was promoted to J1 last season, so I think thatwith Niigata Prefecture and Albirex Niigata to

the day of the contract signing came at thefurther enhance our community contribution

perfect time.

activities.

©ALBIREX NIIGATA

Minako Inazuki
Renewal of naming rights agreement for Denka Swan Stadium

Contributing to the Community and Promoting Healthand Welfare with Niigata Prefecture and Albirex Niigata

18

Denka decided to renew the naming rights partnership agreement for Denka

held in Japan and Korea. It has a seating capacity of approximately 42,300.

Big Swan Stadium, which it has sponsored since 2014, and has signed a new

In terms of attendance, it ranks 10th in the entire J-League and 1st in the J2

agreement through December 31, 2025. A joint press conference was held on

League (average number of visitors from 2018 to 2022).

October 23, with Hideyo Hanazumi, Governor of Niigata Prefecture, Yukio Nakano,Niigata Prefecture is home to Denka’s Omi Plant in Itoigawa City and Gosen

President of Albirex Niigata, and Toshio Imai, President of Denka, in attendance.

Site in Gosen City. The latter is the development and manufacturing base for test

Denka Big Swan Stadium is the home ground of Albirex Niigata, which lastreagents for influenza vaccines and rapid diagnostic kits for COVID-19. Approx-

season returned to the J1 League after a six-year absence. It is a World Athletics

imately 2,000 of the Group’s 6,000 employees work in Niigata Prefecture. By

Class 2 and Japan Association of Athletics Federations (JAAF) Class 1 certified

renewing the contract, Denka aims to engage more deeply with Niigata Prefec-

stadium and was the venue for the opening match of the 2002 FIFA World Cup

ture and its residents, and to support regional revitalization and sports promotion.

The Denka Way | 2023 WinterPolicy Planning Officer
Urban Development Section,
Urban Affairs Bureau, Public
Works Department
Niigata Prefecture

Hiroyuki Kurashina
Sales Division
Albirex Niigata

Eri Tamagawa

Corporate Communication
Dept.
Denka

2023 Winter | The Denka Way

19