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

Halliburton Labs has named its latest members. Photo courtesy of Halliburton

Four new companies have joined Halliburton Labs, the incubator for early-stage energy and climate startups run by Houston energy giant Halliburton.

Halliburton Labs provides the emerging companies with mentorship, industry connections, laboratory access and other resources as they work toward commercialization, according to a news release.

The four new members include:

  • Nandina REM, a Singapore-based company that delivers carbon fiber thermoplastics. It turns end-of-life assets into new, reliable, high-performance materials for the aviation, aerospace and defense industries in a fraction of the time of standard supply chains.
  • Noon Energy, a California-based company that delivers clean, reliable electricity with ultra-long duration energy storage. Its system uses solid oxide electrochemical cells and stores energy as abundant, flexible industrial gases.
  • Proof Energy, a Silicon Valley-based company developed by the Lawrence Berkeley National Laboratory that is commercializing next-generation metallic solid oxide fuel cell (M-SOFC) technology. Its system uses widely available fuels such as ethanol, methanol, ammonia, and natural gas as hydrogen carriers to enable lower-cost, low-emission commercial transportation, and also offers a zero-emission heating solution to preserve battery range in electric vehicles.
  • Tidal Metals, a New Jersey-based company that has developed technology to economically make decarbonized magnesium metal from seawater and electricity.

"Halliburton Labs exemplifies our commitment to advance a secure and pragmatic energy future," Jeff Miller, chairman, president and CEO of Halliburton, said in the news release. "We welcome these companies into our ecosystem, where they will gain access to the tools, expertise, and connections needed to scale their technologies."

Auckland-based Aquafortus Technologies and California-based Sunchem joined Halliburton Labs in September. With the addition of the four new members, the incubator currently supports six early-stage companies.

Read more about the incubator's 2025 cohort here.

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