In the southwestern United States, a remarkable engineering feat has made its debut: the longest conveyor belt in America. Stretching over 42 miles (67 kilometers), this extraordinary structure now transports massive quantities of sand vital for hydraulic fracturing, more commonly known as fracking. The innovative project was launched by Atlas Energy Solutions, headquartered in Texas. The conveyor belt, fittingly named “The Dune Express,” begins its journey in the small town of Kermit, Texas, extending its reach across state lines into Lea County, New Mexico. Resembling a long, steel snake, it glides slowly at speeds of 10 mph – a pace too sluggish for trucks and much longer than any train.
In Kermit, a town with fewer than 6,000 residents, the new behemoth has become a striking sight. Traditionally, sand is transported in this area via large tractor-trailers. Sand plays a critical role in the fracking process, where high-pressure liquid is injected into underground rock, causing fractures that allow oil to escape. The sand works as a propping agent, keeping these fractures from closing as oil, gas, and water flow through them.
According to John Turner, CEO of Atlas Energy Solutions, the traditional truck transport of sand is not only inefficient but also poses significant safety hazards. The immense trucks dominate the roads, particularly in the Permian Basin, a risk-laden area known for its petroleum wealth. Turner expressed that early recognition of the treacherous and inefficient nature of truck transport spurred the development of the conveyor belt, striving to circumvent road traffic complications.
Boasting a carrying capacity of 13 tons (11.79 metric tonnes), the conveyor belt is designed to operate independently of road traffic. The oil and gas sector often paves the way for groundbreaking innovations, and conveyor belts aren’t new in this field. One notable example is a 61-mile-long (98.17 kilometers) conveyor in Western Sahara used to transport phosphorous.
Faced with the challenges of sand transportation by truck, the company saw a bold, high-stakes investment opportunity: a $400 million project to facilitate fracking sand transit. Atlas Energy Solutions transitioned to the public market in March 2023 to secure funding for “The Dune Express,” marking the completion of its initial delivery in January.
The sand primarily travels within a tray-shaped pan, which can be opened at various points, though most of the loading occurs near the Texas-New Mexico border, where it is sold and transported by trucks to its final destinations with fracking companies.
Maintaining the smooth operation of the conveyor poses its own challenges. The alignment of the tray’s rollers is crucial, and turner highlights the importance of monitoring them for potential failures. Sensors embedded in the rollers assist with this task, alerting operators when maintenance is necessary, thereby preventing excessive wear and ensuring continuous operation.
The Dune Express cuts through a vast oil field, an area where environmentalists have voiced concerns about the impact of industry on local wildlife and ecosystems, including that of the sagebrush lizard, listed as endangered. Luke Metzger from Environment Texas raised concerns that the belt could lead to increased drilling in the area, potentially escalating air pollution and spill risks.
Currently, the conveyor belt operates at around half its full capacity for 12 to 14 hours daily, but the company plans to scale up to round-the-clock operations later in the year. In New Mexico, officials including Lea County Commissioner Brad Weber, anticipate the belt will reduce the number of truck and car accidents on a busy parallel highway, offering optimism for improved safety and reduced traffic congestion.
