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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10+ exciting energy breakthroughs made by Houston teams in 2025

Year In Review

Editor's note: As 2025 comes to a close, we're revisiting the biggest headlines and major milestones of the energy sector this year. Here are the most exciting scientific breakthroughs made by Houstonians this year that are poised to shape the future of energy:

Rice University team develops eco-friendly method to destroy 'forever chemicals' in water

Rice University researchers have developed a new method for removing PFAS from water that works 100 times faster than traditional filters. Photo via Rice University.

Rice University researchers have teamed up with South Korean scientists to develop the first eco-friendly technology that captures and destroys toxic “forever chemicals,” or PFAS, in water. The Rice-led study centered on a layered double hydroxide (LDH) material made from copper and aluminum that could rapidly capture PFAS and be used to destroy the chemicals.

UH researchers make breakthrough in cutting carbon capture costs

UH carbon capture cost cutting

A team from UH has published two breakthrough studies that could help cut costs and boost efficiency in carbon capture. Photo courtesy UH.

A team of researchers at the University of Houston has made two breakthroughs in addressing climate change and potentially reducing the cost of capturing harmful emissions from power plants. Led by Professor Mim Rahimi at UH’s Cullen College of Engineering, the team first introduced a membraneless electrochemical process that cuts energy requirements and costs for amine-based carbon dioxide capture during the acid gas sweetening process.The second breakthrough displayed a reversible flow battery architecture that absorbs CO2 during charging and releases it upon discharge.

Houston team’s discovery brings solid-state batteries closer to EV use

Houston researchers have uncovered why solid-state batteries break down and what could be done to slow the process. Photo via Getty Images.

A team of researchers from the University of Houston, Rice University and Brown University has uncovered new findings that could extend battery life and potentially change the electric vehicle landscape. Their work deployed a powerful, high-resolution imaging technique known as operando scanning electron microscopy to better understand why solid-state batteries break down and what could be done to slow the process.

Houston researchers make breakthrough on electricity-generating bacteria

A team of Rice researchers, including Caroline Ajo-Franklin and Biki Bapi Kundu, has uncovered how certain bacteria breathe by generating electricity. Photo by Jeff Fitlow/Rice University.

Research from Rice University that merges biology with electrochemistry has uncovered new findings on how some bacteria generate electricity. Research showed how some bacteria use compounds called naphthoquinones, rather than oxygen, to transfer electrons to external surfaces in a process known as extracellular respiration. In other words, the bacteria are exhale electricity as they breathe. This process has been observed by scientists for years, but the Rice team's deeper understanding of its mechanism is a major breakthrough, with implications for the clean energy and industrial biotechnology sectors, according to the university.

Rice researchers' quantum breakthrough could pave the way for next-gen superconductors

Researchers from Rice University say their recent findings could revolutionize power grids, making energy transmission more efficient. Image via Getty Images.

A study from researchers at Rice University could lead to future advances in superconductors with the potential to transform energy use. The study revealed that electrons in strange metals, which exhibit unusual resistance to electricity and behave strangely at low temperatures, become more entangled at a specific tipping point, shedding new light on these materials. The materials share a close connection with high-temperature superconductors, which have the potential to transmit electricity without energy loss, according to the researchers. By unblocking their properties, researchers believe this could revolutionize power grids and make energy transmission more efficient.

UH researchers develop breakthrough material to boost efficiency of sodium-ion batteries

A team at the University of Houston is changing the game for sodium-ion batteries. Photo via Getty Images

A research lab at the University of Houston developed a new type of material for sodium-ion batteries that could make them more efficient and boost their energy performance. The Canepa Research Laboratory is working on a new material called sodium vanadium phosphate, which improves sodium-ion battery performance by increasing the energy density. This material brings sodium technology closer to competing with lithium-ion batteries, according to the researchers.

Houston researchers make headway on developing low-cost sodium-ion batteries

Houston researchers make headway on developing low-cost sodium-ion batteries

Rice's Atin Pramanik and a team in Pulickel Ajayan's lab shared new findings that offer a sustainable alternative to lithium batteries by enhancing sodium and potassium ion storage. Photo by Jeff Fitlow/Courtesy Rice University

A new study by researchers from Rice University’s Department of Materials Science and NanoEngineering, Baylor University and the Indian Institute of Science Education and Research Thiruvananthapuram has introduced a solution that could help develop more affordable and sustainable sodium-ion batteries. The team worked with tiny cone- and disc-shaped carbon materials from oil and gas industry byproducts with a pure graphitic structure. The forms allow for more efficient energy storage with larger sodium and potassium ions, which is a challenge for anodes in battery research. Sodium and potassium are more widely available and cheaper than lithium.

Houston scientists develop 'recharge-to-recycle' reactor for lithium-ion batteries

Rice University scientists' “recharge-to-recycle” reactor has major implications for the electric vehicle sector. Photo courtesy Jorge Vidal/Rice University.

Engineers at Rice University have developed a cleaner, innovative process to turn end-of-life lithium-ion battery waste into new lithium feedstock. The findings demonstrate how the team’s new “recharge-to-recycle” reactor recharges the battery’s waste cathode materials to coax out lithium ions into water. The team was then able to form high-purity lithium hydroxide, which was clean enough to feed directly back into battery manufacturing. The study has major implications for the electric vehicle sector, which significantly contributes to the waste stream from end-of-life battery packs.

Houston researchers develop strong biomaterial that could replace plastic

A team led by M.A.S.R. Saadi and Muhammad Maksud Rahman has developed a biomaterial that they hope could be used for the “next disposable water bottle." Photo courtesy Rice University.

Collaborators from two Houston universities are leading the way in engineering a biomaterial into a scalable, multifunctional material that could potentially replace plastic. The study introduced a biosynthesis technique that aligns bacterial cellulose fibers in real-time, which resulted in robust biopolymer sheets with “exceptional mechanical properties.” Ultimately, the scientists hope this discovery could be used for the “next disposable water bottle,” which would be made by biodegradable biopolymers in bacterial cellulose, an abundant resource on Earth. Additionally, the team sees applications for the materials in the packaging, breathable textiles, electronics, food and energy sectors.

Houston researchers reach 'surprising' revelation in materials recycling efforts

A team led by Matteo Pasquali, director of Rice’s Carbon Hub, has unveiled how carbon nanotube fibers can be a sustainable alternative to materials like steel, copper and aluminum. Photo by Jeff Fitlow/ Courtesy Rice University

Researchers at Rice University have demonstrated how carbon nanotube (CNT) fibers can be fully recycled without any loss in their structure or properties. The discovery shows that CNT fibers could be used as a sustainable alternative to traditional materials like metals, polymers and the larger, harder-to-recycle carbon fibers, which the team hopes can pave the way for more sustainable and efficient recycling efforts.

UH lands $1M NSF grant to train future critical minerals workforce

workforce pipeline

The University of Houston has launched a $1 million initiative funded by the National Science Foundation to address the gap in the U.S. mineral industry and bring young experts to the field.

The program will bring UH and key industry partners together to expand workforce development and drive research that fuels innovation. It will be led by Xuqing "Jason" Wu, an associate professor of information science technology.

“The program aims to reshape public perception of the critical minerals industry, highlighting its role in energy, defense and advanced manufacturing,” Wu said in a news release. “Our program aims to showcase the industry’s true, high-tech nature.”

The project will sponsor 10 high school students and 10 community college students in Houston each year. It will include industry mentors and participation in a four-week training camp that features “immersive field-based learning experiences.”

“High school and community college students often lack exposure to career pathways in mining, geoscience, materials science and data science,” Wu added in the release. “This project is meant to ignite student interest and strengthen the U.S. workforce pipeline in the minerals industry by equipping students with technical skills, industry knowledge and career readiness.”

This interdisciplinary initiative will also work with co-principal investigators across fields at UH:

  • Jiajia Sun, Earth & Atmospheric Sciences
  • Yan Yao and Jiefu Chen, Electrical and Computer Engineering
  • Yueqin Huang, Information Science Technology

According to UH, minerals and rare earth elements have become “essential building blocks of modern life” and are integral components in technology and devices, roads, the energy industry and more.