The Dune Express

The longest conveyer belt in the U.S. is moving sand in Texas

The Dune Express in West Texas. Courtesy of Atlas Energy

It's longer than the width of Rhode Island, snakes across the oil fields of the southwest U.S. and crawls at 10 mph – too slow for a truck and too long for a train.

It's a new sight: the longest conveyer belt in America.

Atlas Energy Solutions, a Texas-based oil field company, has installed a 42-mile long conveyer belt to transport millions of tons of sand for hydraulic fracturing. The belt the company named “The Dune Express” runs from tiny Kermit, Texas, and across state borders into Lea County, New Mexico. Tall and lanky with lids that resemble solar modules, the steel structure could almost be mistaken for a roller coaster.

In remote West Texas, there are few people to marvel at the unusual machine in Kermit, a city with a population of less than 6,000, where the sand is typically hauled by tractor-trailers. During fracking, liquid is pumped into the ground at a high pressure to create holes, or fractures, that release oil. The sand helps keep the holes open as water, oil and gas flow through it.

But moving the sand by truck is usually a long and potentially dangerous process, according to CEO John Turner. He said massive trucks moving sand and other industrial goods are a common site in the oil-rich Permian Basin and pose a danger to other drivers.

“Pretty early on, the delivery of sand via truck was not only inefficient, it was dangerous,” he said.

The conveyor belt, with a freight capacity of 13 tons, was designed to bypass and trudge alongside traffic.

Innovation isn't new to the oil and gas industry, nor is the idea to use a conveyor belt to move materials around. Another conveyer belt believed to be the world’s longest conveyor — at 61 miles long — carries phosphorous from a mine in Western Sahara on the northwest coast of Africa, according to NASA Earth Observatory.

When moving sand by truck became a nuisance, an unprecedented and risky investment opportunity arose: constructing a $400 million machine to streamline the production of hydraulic fracturing. The company went public in March 2023, in part, to help pay for the conveyor belt and completed its first delivery in January, Turner said.

The sand sits in a tray-shaped pan with a lid that can be taken off at any point, but most of it gets offloaded into silos near the Texas and New Mexico border. Along its miles-long journey, the sand is sold and sent to fracking companies who move it by truck for the remainder of the trip.

Keeping the rollers on the belt aligned and making sure it runs smoothly are the biggest maintenance obstacles, according to Turner. The rollers are equipped with chips that signal when it's about to fail and need to be replaced. This helps prevent wear and tear and keep the machine running consistently, Turner said.

The belt cuts through a large oil patch where environmentalists have long raised concerns about the industry disturbing local habitats, including those of the sagebrush lizard, which was listed as an endangered species last year by the U.S. Fish and Wildlife Service.

“In addition to that, we know that the sand will expedite further drilling nearby,” said Luke Metzger, executive director of Environment Texas. “We could see more drilling than we otherwise would, which means more air pollution, more spills than we otherwise would.”

The Dune Express currently runs for about 12 to 14 hours a day at roughly half capacity but the company expects to it to be rolling along at all hours later this year.

In New Mexico, Lea County Commissioner Brad Weber said he hopes the belt alleviates traffic on a parallel highway where car crashes are frequent.

“I believe it’s going to make a very positive impact here,” he said.

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A View From HETI

John Carrington is now CEO of Enchanted Rock. Photo courtesy Enchanted Rock.

Houston-based electric microgrid company Enchanted Rock has named a new CEO.

John Carrington has assumed the role after serving as Enchanted Rock's executive chairman since June, the company announced earlier this month.

Carrington most recently was CEO of Houston-based Stem, which offers AI-enabled software and services designed for setting up and operating clean energy facilities. He stepped down as Stem’s CEO in September 2024. Stem, which was founded in 2006 and went public under Carrington's leadership in 2021, was previously based in San Francisco.

Carrington has also held senior leadership roles at Miasolé, First Solar and GE.

Corey Amthor has served as acting CEO of Enchanted Rock since June. He succeeded Enchanted Rock founder Thomas McAndrew in the role, with McAndrew staying on with the company as a strategic advisor and board member. With the hiring of Carrington, Amthor has returned to his role as president. According to the company, Amthor and Carrington will "partner to drive the company’s next phase of growth."

“I’m proud to join a leadership team known for technical excellence and execution, and with our company-wide commitment to innovation, we are well positioned to navigate this moment of unprecedented demand and advance our mission alongside our customers nationwide,” Carrington said in the news release. “Enchanted Rock’s technology platform delivers resilient, clean and scalable ultra-low-emissions onsite power that solves some of the most urgent challenges facing our country today. I’m energized by the strong momentum and growing market demand for our solutions, and we remain committed to providing data centers and other critical sectors with the reliable power essential to their operations.”

This summer, Enchanted Rock also announced that Ian Blakely would reassume the role of CFO at the company. He previously served as chief strategy officer. Paul Froutan, Enchanted Rock's former CTO, was also named COO last year.

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