United Power's green steam cuts carbon, lowers costs for Ctg's garment sector

As global manufacturing leans towards low-carbon methods, a quiet shift is emerging in Chattogram, where United Power Generation and Distribution Company Limited is supplying a "green steam" system that turns waste heat from its power plant into usable industrial steam for export-oriented factories.

The system aims to reduce carbon emissions, cut production costs, and support a sustainable supply chain. United Power claims that it saves 20%-50% of the costs of users.

At the heart of this transformation is the company's 72MW natural gas-based power plant in Chattogram Export Processing Zone (CEPZ). Instead of allowing excess heat from electricity generation to escape into the atmosphere, United Power captures this waste heat and converts it into high-pressure steam.

Every day, around 3,50,000kg of steam are supplied to six apparel and dyeing factories, including Pacific Attires, Pacific Jeans, and others.

According to internal estimates, the initiative prevents the emission of 160kg of carbon dioxide per tonne of steam every hour, amounting to a substantial reduction in greenhouse gases for the region.

Turning waste heat into climate-smart energy

During production, the plant's eight generators release exhaust at temperatures of 400°C to 500°C. Instead of wasting this heat, United Power channels it into an exhaust recovery boiler that converts purified water into steam for nearby factories. 

The steam travels through insulated pipelines stretching up to a kilometre from the plant. 

Raqeeb Ashif Haider, assistant manager at United Enterprise and Company, said the system captures heat from each generator and feeds it into a single network. 

"Seven of the eight units are connected, with the final one being prepared for integration to strengthen continuity," he told The Business Standard.

Abu Naser, assistant general manager for operations at United Power, said reliability was central to the design. "The plant has supplied electricity since 2009 and steam since 2014." 

One generator is always kept in reserve, ensuring factory operations continue uninterrupted, he said, adding that the automated system lowers output gently if gas pressure falls but never shuts down entirely.

Naser said the plant generates 72MW of electricity, sending 50MW to the CEPZ and 20MW to the Korean EPZ. Combined demand in the two zones stands between 105MW and 110MW. Night-time demand at the CEPZ drops to as low as 25-30%, allowing excess power to flow into the grid.

Cleaner and cheaper

The environmental and economic benefits of green steam become clearer when compared with traditional methods. Apparel factories typically generate their own steam by burning natural gas, LPG, diesel, or coal in large industrial boilers. But this method is costly and carbon-intensive.

"Using our green steam reduces factory energy consumption by 12% compared to gas-based boilers," said Abu Naser. "If factories used LPG, their cost would rise by 55%. With diesel, it would be 65% higher."

Each year, the plant delivers millions of kilograms of steam to support dyeing, finishing, and production lines across several factories. United Power supplies steam only within the EPZ, with Bangladesh Export Processing Zones Authority (Bepza) receiving a 10% royalty.

"No other private company can simply build a plant and sell steam like us," a United Power official said. "We operate under Bepza's integrated infrastructure and safety framework, which guarantees reliability."

Step towards climate goals

United Power's initiative supports several Sustainable Development Goals, including affordable clean energy, sustainable industrialisation, responsible production, and climate action. 

The company has already received the SDG Brand Champion Award 2025 and the Asian Innovation Excellence Award 2025 for its work.

"Green steam helps factories cut their carbon footprint significantly," said Rahat Bin Kamal, head of investment and General Manager of United Group's Power Division. He said the system reduces environmental impact while supporting brands committed to climate-friendly sourcing.

Experts said with apparel exports exceeding $40 billion annually, environmentally responsible energy systems are essential for maintaining global competitiveness. 

Ahmad Kamruzzaman, chairman of Centre for Atmospheric Pollution Studies, told TBS, "When anything burns, it produces carbon emissions. Using the generated carbon or steam for other purposes benefits the economy and helps combat climate change."