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

Texas outpaced all other states in various categories of power generation in 2024, according to a new report from Ember, an energy think tank. File photo

The winds of change in power generation are sweeping through Texas.

Texas outpaced all other states in various categories of power generation in 2024, according to a new report from Ember, an energy think tank. The report shows:

  • Texas contributed more (12 terawatt-hours) to the country’s 64 terawatt-hour rise in solar generation last year than any other state.
  • Texas installed more solar (7.4 gigawatts) and battery (3.9 gigawatt) capacity than any other state.
  • Texas installed more utility-scale battery capacity (3.9 gigawatts) than any other state.
  • Texas saw the second biggest increase (eight terawatt-hours) in natural gas generation in 2024. Only Virginia, at 10 terawatt-hours, ranked higher.
  • Texas ranked second among the states for the biggest drop in production of coal-fueled power (6.07 terawatt-hours), preceded only by Wyoming (6.3 terawatt-hours).

Overall, coal represented 14 percent of power generation in Texas last year, with the combination of wind and solar at 30 percent, according to the report. Across the U.S., says the report, wind and solar generated more electricity than coal for the first time. Coal generation made up just 15% of U.S. electricity generation in 2024.

“The shift away from coal has been primarily driven by market dynamics and availability of more cost-effective resources,” the report says. “The unit costs of wind and solar have reduced significantly and their quick installation makes them commercially attractive.”

Citing data like the figures published by Ember, Texas Gov. Greg Abbott champions Texas as the “Energy Capital of the World,” a title that Houston also claims.

“As Texas continues to experience unprecedented growth, we will remain a leader in energy while also bolstering the Texas grid to meet the growing demands of our great state,” Abbott said in 2024.

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