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

Houston-based HEXASpec took home the top TEX-E prize and $25,000 at last year's Energy Venture Day and Pitch Competition. Photo courtesy TEX-E.

The Rice Alliance for Technology and Entrepreneurship, the Houston Energy Transition Initiative (HETI), the Texas Entrepreneurship Exchange for Energy (TEX-E) and the Ion have named the 30-plus energy ventures and teams that will pitch at the 2026 Energy Venture Day and Pitch Competition during CERAWeek this month.

The selected ventures are "driving efficiency and advancements toward the energy transition," according to the Rice Alliance. Each will each present a 3.5-minute pitch before a network of investors and industry partners during CERAWeek's Agora program on Wednesday, March 25, from noon-5:30 p.m.

The competition is divided up into the TEX-E university track, in which Texas student-led energy startups compete for $50,000 in cash prizes, and the industry ventures track.

Teams competing in the TEX-E Prize track include:

  • GOES
  • Quantum Power System
  • Quas
  • Resonant Thermal Systems
  • Srijan

The industry track is subdivided into three additional tracks, spanning materials to clean energy and will feature 37 companies. A group of expert judges will name the top three companies from each industry track. The winner of the CERAWeek competition will also have the chance to advance and compete for the $1 million investment prize at the Startup World Cup in November 2026.

Teams come from around the world, including several Houston-based ventures, such as Agellus Tank Robotics, Capwell Services and Corrolytics.

The full list of companies pitching at CERAWeek includes:

  • Agellus Tank Robotics
  • Airovation Technologies
  • Anax Power
  • Armeta
  • ATS Energy
  • Capwell Services
  • CarbonLume
  • Cogniprise
  • Corrolytics
  • Daphne Technology
  • Gemini Energy
  • Grid8
  • H Quest Vanguard
  • intcom
  • Ionada Canada
  • Junipix
  • Kunin Technologies
  • LAVA Power
  • Licube
  • LNK Energies
  • Maverick X
  • Membravo
  • Mirico
  • Mocean Energy
  • Monitorai
  • OCOchem
  • Oleo
  • Pix Force
  • PolyJoule
  • Power to Hydrogen
  • Sotaog
  • Spotlight
  • Tierra Climate
  • Verdagy
  • Via Separations
  • Vycarb
  • ZettaJoule

Those not attending CERAWeek can catch these companies and more than a dozen others at a pitch preview at the Ion. The free Pitch Preview will be held Tuesday, March 24, from 9 a.m.-2:30 p.m. Click here to register.

Additional companies pitching during the free preview include:

  • Ammobia
  • Arolytics
  • Ayrton Energy
  • ChainWeave
  • Cybereum
  • Energytech
  • ENP Technologies
  • KP Labs
  • Mcatalysis
  • Mitico
  • Mote
  • Nanos
  • New Horizon Oil and Gas
  • Predyct
  • Salem Robotics
  • Toluai

Two Rice University student teams took home top prizes during last year's TEX-E competition, while ventures from New Jersey, Wyoming and Virgina won in their respective industry tracks. See the full list of last year's winners here.

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