Mapped: The 42-Mile-Long ‘Dune Express’ Texas Conveyor Belt

A new, record-breaking conveyor belt is changing how sand is transported for hydraulic fracturing across the southwest United States.

Spanning 42 miles, Atlas Energy Solutions’ “Dune Express” is the longest conveyor belt in the country, cutting across oil fields from Kermit, Texas, to Lea County, New Mexico.

A Safer Alternative to Trucks

The conveyor belt offers a safer, more efficient alternative to truck transport, which has long been the primary method for moving sand used in fracking.

The Permian Basin, one of the nation’s most productive oil fields, sees heavy truck traffic that increases road congestion and accident risks. By reducing reliance on trucks, Atlas Energy Solutions aims to streamline operations and enhance safety.

CEO John Turner said the traditional method of hauling sand via truck had become increasingly inefficient and hazardous. “Pretty early on, the delivery of sand via truck was not only inefficient, it was dangerous,” Turner said.

What to Know

The $400 million Dune Express, which became operational in January, can transport up to 13 tons of sand at a time.

The covered steel structure runs parallel to highways, designed to bypass heavy traffic while ensuring a continuous supply of sand to fracking sites.

The structure is reminiscent of a roller coaster, with its tall frame and lids resembling solar panels. The design also allows sand to be off-loaded at multiple points along its route, ensuring timely distribution to fracking companies.

Conveyor belts are not new to industrial transport. What is believed to be the world’s longest conveyor, at 61 miles, moves phosphorus from a mine in Western Sahara, according to NASA Earth Observatory.

In the U.S., the Dune Express is an unprecedented investment in fracking logistics.

The company went public in March 2023 to help fund the project, with hopes that its efficiency will revolutionize the industry.

What People Are Saying

The introduction of the conveyor belt has drawn mixed reactions from industry and environmental groups.

Lea County Commissioner Brad Weber believes the belt will ease traffic on local highways notorious for frequent accidents. “I believe it’s going to make a very positive impact here,” Weber said.

However, environmental groups warn the belt could accelerate fracking activity. Luke Metzger, executive director of Environment Texas, voiced concerns about the broader impact.

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

What’s Next

Currently, the Dune Express operates 12 to 14 hours per day at about half capacity. Atlas Energy Solutions plans to ramp up operations to a full 24-hour schedule later this year.

Ongoing maintenance will be critical to sustaining efficiency. Turner noted that the belt’s rollers are equipped with chips that signal when they are about to fail, allowing for proactive replacements.

This article uses reporting by The Associated Press.