While striving for safe and stable plant operation, we are engaged in the development and practical use of various evaluation technologies to ensure safety at each stage, from R&D and manufacture to transport and disposal.
Viewing safety as the foundation of business activities, Mitsubishi Chemical Corporation (MCC) is engaged in safety activities targeting zero facility-related accidents. Despite its efforts, however, The Mitsubishi Chemical Corporation Group (MCC Group) has experienced several accidents. In 2007, a major accident took the lives of four affiliate employees at the Kashima Plant. Additionally, in 2008, one employee of an affiliate was seriously injured in a fire at the Kurosaki Plant.
Fully realizing the seriousness of these accidents, the MCC Group is implementing the APTSIS 10 midterm management plan with a particular focus on reemphasizing Safety First Awareness and strengthening worksite professional skills as objectives related to production division security. To this end, MCC carries out thorough accident recurrence prevention measures and promotes the review of facility safety measures and standards. With eyes fixed on the goal of zero facilityrelated accidents, the Group will also maintain the following three activities that have been a part of its safety initiatives to date.
To reduce risks associated with potential hazards, safety inspections are performed in three areas - existing processes, facilities, and procedures.
As a measure to address the aging of facilities, the MCC Group began in fiscal 2004 to implement stricter facility inspections. In addition, since fiscal 2007, we have continued reviews of facility inspection plans and other aspects of management in an attempt to improve the level of security.
Super-Stable Operation Technologies (SSOT) and Super-Stable Maintenance Technologies (SSMT) are being developed and implemented to provide technical support to efforts to achieve super-stable operations.
The MCC Group has conducted Safety Assessment (SA) Activities for evaluating production method and process safety in the development, construction, and operation phases of efforts aimed at starting the production of new products or improving existing processes.
In fiscal 2008, SAs were thoroughly implemented with regard to daily operating conditions and changes in operation and standards were revised to require the presence of SR instructors1 from outside of the relevant department when conducting SAs.
For existing processes, facilities, and work procedures, the Group established SR instructors at all plants and factories in 2003. These teams comprehensively, systematically, and continuously evaluate risks associated with potential hazards and have pursued Safety Review Activities aimed safety conditions to higher levels.
Gas explosion evaluation equipment
(The only facility granted an approval under the High Pressure Gas Safety Act in Japan)
In an attempt to enhance the safety of existing technologies and measures, the MCC Group established a Safety Engineering and Environmental Integrity Laboratory at the Mitsubishi Chemical Group Science and Technology Research Center.
To prevent fires, explosions and hazardous substance leakage during product R&D, manufacturing, transport, use and disposal, this laboratory works to advance chemical substance hazard prediction and verification technologies as well as process risk evaluation technologies. It also disseminates safety technology information to the entire MCC Group.
The latest safety-related technology and information is provided to the production sites during SR and SA implementation, improving plant reliability.
Also, in the event of an accident or trouble, the laboratory will thoroughly investigate the cause from a scientific point of view and propose essential safety measures to prevent recurrence. In fiscal 2008, the laboratory established evaluative technologies to investigate the cause of the December 2007 fire at the Kashima Plant.
Yoichi Kunito
Production Technology Research and Environmental Safety Engineering Laboratory Chief Mitsubishi Chemical Group Science and Technology Research Center, Inc.
Going forward, we must systematically brush up each evaluation technology to heighten the precision of existing safety technology, which I believe is directly linked to improved reliability.
In addition, if we revise processes with the goal of improving productivity and rationalization of the existing plants, we will be able to identify potential hazards. We must investigate tangible safety measures and thoroughly carry them out, inculcating safety awareness among all employees involved in plant technology and operation. In support of these objectives, starting in fiscal 2009 we plan on holding safety education lectures conducted by laboratory staff. We will continue our efforts to heighten and promote evaluation technologies.
Tanker truck leakage drill
MCC, together with Mitsubishi Chemical Logistics, works to prevent distribution-related accidents. It also holds accident prevention drills for various types of distributionrelated accidents at least once a year at its major logistics centers. Weaknesses identified through training are immediately rectified, and a system capable of responding smoothly to emergencies has been put in place.
