Whitefox Technologies is advancing ethanol distillation, dehydration and evaporation (DD&E) by replacing molecular sieves with membrane technology, achieving up to 50% reductions in both energy and water consumption in the most energy-intensive plant operation.
As ethanol producers seek new efficiencies and lower carbon intensity scores, operational strategies are evolving. Beyond incremental process optimizations, plants are investing in infrastructure capable of supporting long-term decarbonization and readiness to navigate regulatory change. Western Plains Energy identified Whitefox ICE® XL as a key asset in its Net Zero strategy. Commissioned in October 2024, this system delivers substantial operational efficiencies and resource savings.
“This project is probably the largest step change you can make in energy, period,” said Western Plains CEO Derek Peine. “We set the goal to become a Net Zero carbon intensity fuel supplier. We’re on the path and this project is helping us get there.”
The ICE XL system introduces two core improvements:
• Membrane-based dehydration, replacing molecular sieves for immediate efficiency gains
• Reengineered DD&E energy management, leveraging proprietary heat integration to further reduce energy demand
Whitefox’s initial product for the U.S. ethanol market, the Whitefox ICE system, integrates a membrane unit alongside existing molecular sieves as a bolt-on debottlenecking solution. The system processes regen streams without pressure fluctuations or reflux loops, improving process stability and uptime. Its broad operating range accommodates streams with up to 50% moisture, while proprietary heat recovery reintegrates latent energy from the ICE system, reducing thermal loads and cutting natural gas consumption by 10–15%.
Restructuring the Energy Equation In DD&E
The Whitefox ICE XL removes molecular sieves entirely, enabling a new energy optimization model for ethanol downstream processing.
“The way that the traditional DD&E system was designed was the best way to go about it with the molecular sieve incorporated,” said Jeff Scharping, Commercial Director at Whitefox. “However, once you swap in the membrane, it changes the variables you use to design the system, changing the energy equation, and allowing it to use the energy more times throughout, ultimately delivering a 50% reduction in natural gas consumption.”
By starting with energy optimization that doesn’t increase electrical load, it allows producers to broaden their strategies to include additional technologies, such as Mechanical Vapor Recompression (MVR), as they continue on the path towards Net Zero. In addition, the Whitefox ICE XL reduces cooling water demand by 50%, addressing limitations in water-scarce regions and facilities constrained by cooling tower capacity.
“This project helped us not only have a sustainable future for the bottom line, but also be able to use fewer natural resources,” said Rick Holaday, Western Plains Plant Manager.
As ethanol producers pursue carbon reduction strategies and operational resilience, early adopters like Western Plains demonstrate how infrastructure investments can deliver immediate resource savings while positioning plants for long-term regulatory and market shifts.
“At Whitefox, we appreciate the challenge that ethanol producers take on as they look towards the next 25 years,” said Whitefox CEO Gillian Harrison. “We are doing the same as we celebrate our 25th anniversary in 2025. Regardless of market influences, one thing we can bet safely on is the value in reducing operating costs and scaling back reliance on natural resources. Helping industry to do that, plant by plant, is how we achieve our mission to produce more with less.”
By the end of 2025, membranes will be operational in 16 North American plants, with several sites demonstrating membrane lifespans exceeding four years under continuous operation. For technical specifications and project inquiries, visit Whitefox.com or email solutions@whitefox.com.
