CASE STUDY:  

Record-Breaking Conveyor System

Engineering the Impossible: SEW-EURODRIVE Powers the World’s Longest Single-Flight Conveyor

An unprecedented feat of industrial automation, the Dune Express conveyor system transformed a complex, large-scale challenge into a streamlined, high-performance reality. This was made possible by SEW-EURODRIVE’s world-class engineering, precision-built drive technology, and seamless execution from design through commissioning.

  • 42-mile single-flight conveyor system
  • 13 Million Tons per year capacity
  • Built for reliability. Engineered to last.

 Challenge:

Engineering for Unprecedented Scale

Prior to the commissioning of the Dune Express, Atlas Energy Solutions relied solely on trucks and roadways to transport frac sand for its large-scale operations. The proposed solution was the 42-mile Dune Express conveyor system that runs from Kermit, TX, to just beyond the Texas/New Mexico line. The proposed system would shorten the distance that the sand travels, with the expectation of significantly minimizing the number of trucks on the road, miles driven, and associated emissions, all while driving efficiency gains at the wellsite.

To support the second-largest conveyor in the world, designed for a throughput capacity of up to 13 million tons of frac sand annually, end-user Atlas Energy Solutions and system integrator Voith Turbo needed ultra-reliable mechanical drive technology.

The application demands were extreme: extended duty cycles, brutal desert sun, and rugged terrain. Each drive system required advanced thermal validation, high torque capacity, and seamless electro-mechanical integration.

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X.e Series Gear Unit
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42-Mile Dune Express Conveyors System

Solution:

X.e Series Industrial Gearboxes Engineered for Performance

SEW‑EURODRIVE supplied 36 X.e Series helical-bevel heavy-industry gear units, engineered for high torque, reliability, and application-specific thermal requirements.

To meet thermal requirements, each gearbox was equipped with synthetic GearOil® by SEW-EURODRIVE and configured with either splash lubrication with shaft fans or pressure lubrication with oil-to-air cooling systems, depending on duty-cycle demands. SEW engineers collaborated closely with Voith to deliver:

  • Gearbox sizing matched to application dynamics
  • Thermal performance modeling and bearing life analysis
  • Delivery logistics and on-site commissioning support
  • Fabrication and fit verification for mechanical interfaces
  • Condition monitoring sensors and safety guarding specs

 "Engineering for a 42-mile conveyor takes more than knowing horsepower — it takes understanding the unique application dynamics, thermal insight, and logistics at scale. Our X.e gear units and amazing SEW Team delivered on every front." 
— Austin Burdette, Heavy Industry Gearing Product Manager, SEW-EURODRIVE USA

 

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The SEW-EURODRIVE Advantage:

  • Built for performance under pressure
  • U.S.-based engineering, assembly
  • 36-custom gear units delivered on schedule
  • Full system support from design to commissioning

Application Summary:

Application Area

Conveyor Name

SEW-EURODRIVE Products

Nominal Output Torque [lb-in]

Ratio

Power [HP]

Long-distance conveyance

105-CV-001

X3KR190e/HU/B

598,314

20.29

300

100-CV-101

X2KR170e/HU/B

420,413

11.08

300

SL-CV01

X2KR170e/HU/B

420,413

11.08

300

EV-CV01

X2KR170e/HU/B

420,413

11.08

300

EL-CV02
EL-CV03

X2KR130e/HU/B

137,187

11.28

100

110-CV-002
115-CV-003
120-CV-004

X3KR240e/HU/B

1,460,382

20.36

900

All

  • X.e Series gear units

  • GEN1 cooling and lubrication systems

  • GearOil by SEW-EURODRIVE

 

 

 

High-torque drive segments

All

  • X.e Series gear units
    Custom coupling & guards

  • Installation of gear units on swingbases

  • Alignment and installation of motors and couplings

Electrified system integration

All

  • Full mechanical drive assemblies

  • In-house and on-site wiring support

Condition monitoring & safety

All

  • Integrated sensors (e.g. oil flow, oil
    temperature, oil humidity/moisture, oil
    level, oil particle, bearing temperature,
    provisions for bearing vibration)

  • Panel wiring

  • Interface design

CUSTOMER:

Voith Turbo  
Atlas Energy Solutions Inc. (NYSE: AESI) 
Austin, TX

INDUSTRY:

Oil & Gas
Oilfield Logistics / Bulk Material Handling

APPLICATION:

Fully electrified 42-mile single-flight overland frac sand conveyor system 

PREVIOUS TECHNOLOGY:

Trucks and Roadways

SOLUTION:

X.e Series Helical-bevel Gear Units
Condition Monitoring
GearOil by SEW-EURODRIVE

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About SEW-EURODRIVE

Founded in 1931 in Bruchsal, Germany, SEW-EURODRIVE is a global leader in Industrial Automation, with operations in over 50 countries, 17 manufacturing plants, 92 assembly facilities, and more than 21,000 employees. The company holds over 1,000 patents, continuously driving technological advancements in gearmotors, frequency inverters, servo drives, and Industry 4.0 solutions.

SEW-EURODRIVE provides engineered solutions in countless industries, including automotive, food & beverage, pharmaceuticals, mining, steel, logistics, energy, and more, providing customized automation solutions that enhance efficiency, productivity, and sustainability. Despite its global reach, SEW-EURODRIVE remains family-owned, ensuring long-term vision, strong values, and a commitment to excellence.

SEW-EURODRIVE. Driving the World™

SEW-EURODRIVE, Inc.
220 Finch Road
Wellford, SC 29385
(P): (864) 439-7537
cslyman@seweurodrive.com
www.seweurodrive.com 

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