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- Environmental Activities: Reduction in Greenhouse Gas Emissions
The AGC Group is committed to energy conservation and the emission reduction of fluorinated greenhouse gases. We are also fostering the technological development, manufacture, and use of solar cell materials and low-emissive double-glazing glass (Ecoglass) as products to help reduce CO2 emissions from society at large.
Asahi Glass participates in the Japanese government's “Experimental Introduction of an Integrated Domestic Market for Emissions Trading.” For the first commitment period of Kyoto Protocol (2008 to 2012), we have set the target of reducing CO2 emissions in our manufacturing process by approximately 1% from the average level for 2006 and 2007. To this end, we are striving to reduce our CO2 emissions.
Reducing CO2 emissions from manufacturing sites and offices
In fiscal 2008, Asahi Glass reduced CO2 emissions from the use of energy in its manufacturing process by 36% from the level in the baseline year (1990) of the Kyoto Protocol. We could achieve this mainly for the following reasons: domestic business restructuring; fuel conversion for glass furnaces; the improvement of our manufacturing process through the total oxygen combustion and all-electric melting methods; and the introduction of a cogeneration system. Moreover, we are also conducting activities at our offices. For example, we allow employees at our Asahi Glass head office to wear casual attire at their workplaces and set the thermostats of air conditioners at more environmentally friendly temperatures.
Reducing emissions of greenhouse gases other than CO2
As for greenhouse gases other than CO2, Asahi Glass manufactures and sells fluorinated gases, namely HFC, PFC, and SF6. These gases have much higher global warming potentials than CO2. In light of this fact, we have been aggressively reducing the emissions of these gases from our manufacturing processes and are also promoting their recovery and recycling. As a result, we reduced their emissions by 95% from the baseline year (1995) of the Kyoto Protocol in fiscal 2008. The amount thus reduced is approximately 30% of the total reductions achieved in Japan in fiscal 2007. In addition, we have been recovering fluorinated gases from our customers and breaking down and recycling them since fiscal 1997.
Emissions of Greenhouse Gases (including CO2 and Fluorinated Gases)
*1 In fiscal 2006, we changed the CO2 conversion factor for electricity from each individual electric power companies' indicators to the statutory factor (0.555 tons-CO2/MWh), and this has led to a nominal increase of 10% in CO2 emissions.
*2 The scope of data varies by fiscal year.
The AGC Group's Total Energy Consumption in Fiscal 2008
The AGC Group's Greenhouse Gas Emissions in Fiscal 2008
*Figures in parentheses are results in fiscal 2007.
*The total energy consumption and greenhouse gas emissions do not always add up to 100% because of rounding.
Topic
Reducing CO2 emissions by about 14,500 tons per year through the effective use of hydrogen generated from brine electrolysis (Japan)
Hydrogen boiler contributing to substantial CO2 emission reductions
Asahi Glass Kashima Plant used to use part of the hydrogen generated from brine electrolysis as boiler fuel. The electrolysis process was usually conducted during the night for manufacturing caustic soda and other products, and not all of this large volume of hydrogen thus produced was utilized as boiler fuel. Furthermore, hydrogen had to be supplied to the equipment at a certain fixed pressure level. To adjust the pressure, some of the generated hydrogen was discharged into the air. To solve this problem, the plant installed a hydrogen holder for pressure adjustment and reduced the discharge of hydrogen into the air to zero. At the same time, it introduced a new hydrogen boiler with high processing performance to enable all the generated hydrogen to be used as boiler fuel. As a result, the plant saved energy at a rate of about 6,350 kiloliters per year in oil equivalent, thereby reducing its CO2 emissions by approximately 14,500 tons annually.
In recognition of this initiative, the plant received the ECCJ Chairman's Award at the National Contest of Energy Conservation Successful Cases for fiscal 2008.
Reducing CO2 emissions by 140,000 tons a year by introducing a new gas turbine (Japan)
Gas turbine power generator newly introduced to the Chiba Plant
Asahi Glass Chiba Plant has replaced its heavy oil-powered gas turbine power generator with a natural gas-powered one to substantially reduce soot, dust, and SOx generation. For the new gas turbine, an aircraft engine is used for higher thermal efficiency and more advanced combustion control, which results in an outstanding reduction in NOx generation. In addition, the plant can now make full use of the natural gas it exploits and has substantially reduced its environmental impact.
- CO2 emissions: 25% reduction (approx. 140,000 tons/year)
- Energy intensity: 8% reduction (energy conservation of 21,000 kl/year in oil equivalent)
- SOx: 92% reduction (approx. 22,000 Nm3/year)
- NOx: 49% reduction (approx. 108,000 Nm3/year)
- Soot and dust: 62% reduction (approx. 10 tons/year)
Receiving the Agency for Natural Resources and Energy Director-General's Award for Ongoing Energy Conservation Activities (Japan)
Award ceremony for the Commendation Program to Excellent Energy Management Factories
AGC Display Glass Yonezawa (ADY) manufactures glass substrates for fl at panel displays. As part of its ongoing commitment to energy conservation, ADY replaced the heating system used in its administrative building in fiscal 2007 with a pump-type heater that utilizes hot water generated in the manufacturing process, resulting in an approximately 100-ton reduction in CO2 emissions on an annual basis. Moreover, over three years from 2005, ADY implemented five energy conservation projects, including using waste heat from the manufacturing process. As a result, it reduced its energy intensity in fiscal 2007 by approximately 30% from the fiscal 2004 level.
In February 2009, in recognition of these efforts, ADY was granted the Agency for Natural Resources and Energy Director-General′s Award under the Commendation Program to Excellent Energy Management Factories held by the Energy Conservation Center, Japan (ECCJ).
Effects of the Total Oxygen Combustion Method
Mechanism of the total oxygen
combustion method
Asahi Glass introduced the total oxygen combustion method to the Keihin Plant in 2001, which was a first in flat glass production in Japan. This method sends only oxygen to a glass melting furnace instead of air, which contains a large amount of nitrogen (an element unrelated to combustion). Oxygen and atomized fuel oil are jetted in through a fuel injection port installed on the left and right sides of a glass melting furnace, as shown in the figure on the right, to scatter the fuel-oxygen mixture for a uniform heating of the furnace interior.
This method was employed to reduce the generation of substances that have an environmental impact, such as NOx, SOx, and dust and soot. It is particularly effective in reducing NOx because the combustion gas contains almost no nitrogen, thus helping to curb NOx generation itself.
The effectiveness of the total oxygen combustion method has been well proven since its introduction at the Glass Department of the Keihin Plant of Asahi Glass. In fact, NOx, SOx, and dust and soot emissions per unit glass production were reduced approximately 90%, 70% and 80%*3, respectively, from prior to the introduction of the method. Similarly, energy consumption and CO2 emissions per unit glass production were also reduced about 30%*3 each.
Changes in NOx emissions per unit production of glass product*3  |
Changes in SOx emissions per unit production of glass product*3  |
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Changes in dust and soot emissions per unit production of glass product*3  |
Comparison of emissions and energy consumption per unit production of glass product*3  |
*3 Data as of 2002
Reducing CO2 Emissions from Transportation
The revised Act Concerning the Rational Use of Energy was put into effect in April 2006. As a “Specified Consigner”*4 defined by the law, Asahi Glass has been reducing per-unit CO2 emissions from its transportation activities, setting fiscal 2006 as the baseline. Our transportation volume totaled 850 million ton-kilos*5 (equivalent to 69,000 tons of CO2 emissions per year) in fiscal 2006 (from April 2006 to March 2007).
In fiscal 2007 (from January to December 2007), we reduced both our CO2 emissions per ton-kilo and CO2 emissions per ton of shipment by 3.6%. (We use the former as an efficiency indicator for our entire transportation activities and the latter as a management indicator.)
In fiscal 2008 (from January to December 2008), partially due to substantial changes in our business environment, including periodical repair of our main manufacturing plants, our CO2 emissions per ton-kilo decreased by 3.9% from the fiscal 2006 level, but emissions per ton of shipment increased by 0.8%.
We will further strengthen our CO2 emission reduction measures in the transportation field. Specifically, we will improve our transportation efficiency by consolidating our bases, promoting modal shift, upsizing transportation vehicles, and expanding the use of low-emission vehicles, while making effective use of local ports and arranging joint transportation with other companies. Furthermore, by avoiding idling and encouraging “eco-driving,” we will make ourselves even more environmentally conscious.
*4 Under the law, companies that consign freight transportation of a volume of 30 million ton-kilos or more per year are classified as “Specified Consigners.” There are 865 Specified Consigners in Japan (as of the end of June 2008).
*5 When freight weighing one ton is carried over one kilometer, the transportation volume is represented as one ton-kilo.
Modal shift and its effect
Modal shift means shifting from road transportation by truck to railroad and ship transportation, which enables products to be transported in larger quantities with less environmental impact.
Effect 1: Reduction in energy use (CO2 emissions)
It is generally said that CO2 emissions from truck transportation are approximately eight and four times as large as those from railroad and ship transportation, respectively.
Effect 2: Mitigation of traffic jams and prevention of traffic accidents
Reducing transportation distances by truck will be effective in preventing traffic accidents.
Topic
Reducing CO2 emissions by the effective use of local ports
Asahi Glass shortens its domestic road transportation distance to its delivery destinations by the use of local ports. The use of local ports is useful in reducing CO2 emissions, as well as in avoiding traffic congestion.
In the past, we transported our products, which were manufactured overseas and landed at major international ports in Japan, including Yokohama and Kobe, to our plants and customers all over the country by truck. Recently, however, the number of local ports dealing with import/export container freight has been increasing, and so we started actively using newly available container shipping routes.
Reducing CO2 emissions by joint transportation with other companies
AGC Logistics Co., Ltd. as a company specializing in transportation for the AGC Group, is promoting joint transportation with other companies located near the plants of the AGC Group, in order to improve the efficiency of its domestic transportation by truck and decrease its CO2 emissions. This joint transportation initiative, generally known as a “milk run,” enables efficient transportation by loading freight from different companies together on the same truck. For example, AGC Logistics engages in as many as 1,500 joint transportation runs per month for the AGC Group's flat glass used for construction, among other items. In accordance with an increase in freight volume and in line with the promotion of joint transportation, large-sized trucks, rather than the 2- and 4-ton trucks mainly used for delivery in the past, are being increasingly used, resulting in reductions in CO2 emissions.
In addition, the transportation company loads and delivers the freight of other companies after unloading the freight consigned by its own customers at the delivery destinations, and shares depots with other companies. AGC Logistics is thus implementing a range of measures geared towards the further rationalization of its transportation activities.
Premises for estimating the annual number of trucks used for transportation by load capacity
Traditional method: Number of trucks that would have been used for transportation if each company had individually transported the freight consigned by its customers during the period from January 1, 2006 to December 31, 2006
Improved method: Number of trucks used for joint transportation during the aforementioned period
Using “Simple Pallets” to Improve Transportation Efficiency
The AGC Group has introduced a returnable steel pallet known as a “simple pallet” for the importing and transporting of flat glass.
For this repeatedly usable pallet, we received the Chairman's Award in the Clean Japan Center's Resource Recycling Technology and Systems Awards (for fiscal 2006) held by the Center and supported by the Ministry of Economy, Trade and Industry.
The AGC Group independently developed the simple pallet as a packaging method replacing conventional wooden transportation boxes, and introduced this pallet in 2000. At present, these pallets are used for 80% of the Group's imports of sheet glass from Thailand and Indonesia to be processed in Japan. As a result, we were able to reduce our use of wood by as much as 24,000 m3 in volume on an annual basis. In addition, empty pallets can be compactly stacked for return, resulting in higher efficiency in transportation.
We will further make improvements to our simple pallet so that it can be used for various other products.
 Simple pallet used for shipment |
 Empty pallets compactly stacked together for return |
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