The history of the UK’s nuclear industry is long and fascinating, marked by periods of pioneering innovation, significant challenges, and ultimately, enduring relevance. Dating back to the Second World War, British scientists were paramount in the development of the first atomic weapons.
Post-war, the industry saw a change, with focus shifting to peaceful applications, building the world’s first commercial nuclear reactor at Calder Hall in the 1950s. Magnox and AGR reactors followed, supplying a significant chunk of the UK’s electricity.[1] However, safety concerns, and the Chernobyl disaster in the late 80s eroded public trust. New builds slowed, and managing existing facilities became the priority. Despite the initial setback, the industry never fully shut down.
Today, with net-zero targets driving energy policy, there’s a renewed focus on clean energy and nuclear as a reliable energy source. Birchwood Park stands as a prime example of the resurgence of the nuclear sector, acting as a hub for innovation within the UK’s nuclear industry.
Recognised as one of the most successful centres for nuclear services in the UK, Birchwood Park features a roster of some of the most prominent global nuclear organisations within in its world-class hub.
Home to over 165 companies with over 40% working within the nuclear field, the Park is positioned as a leader in the UK’s nuclear revival with many of its nuclear-based occupiers operating in purpose-built facilities, to produce some of the most innovative engineering projects in the industry.
Here we explore the transformation of this thriving cluster, looking back at the site’s rich history whilst showcasing some of the industry’s most pioneering projects along the way.
History of the Nuclear Cluster
Ordnance factory to world class nuclear hub
The history of the site dates back to the 1930s, where the construction of Risley Royal Ordnance Factory (ROF) commenced, following the victory in WWI.[2] Covering most of the areas now known as Birchwood, Oakwood and Gorse Covert in the north west, the ROF produced over 1 million mines and half a million high explosive bombs throughout WW2.
In 1946, the UK Government announced its decision to set up an atomic energy (production) organisation in support of its defence requirements, as part of the Ministry of Supply and the ROF Risley site was selected as the headquarters for the development. 1954 saw the formation of the United Kingdom Atomic Energy Authority (UKAEA), taking over the atomic energy functions of the Ministry of Supply[3], where the genesis of the nuclear sector, at the future Birchwood Park site began.
Issuing the Programme for Nuclear Power in 1955, the UK Government delegated the UKAEA Industrial Group the fundamental role of the development of economic nuclear power. Supplying fuel elements for the 1st phase of reactors (Magnox reactors), the UKAEA were responsible for receiving and processing irradiated fuel from the UK and those reactors. By 1956, the UKAEA established a centre for nuclear research and development to oversee all aspects of the nuclear fuel cycle in the UK, from new build to eventual decommissioning.[4]
Rise of the thriving nuclear community
Since the arrival of the UKAEA on the site, the industry group were able to diversify into commercial and non-nuclear activity. But as the central authority, the UKAEA played a pivotal role in establishing important safety protocols industry wide, whilst conducting extensive research into nuclear waste and environmental impact.
The UK’s civil nuclear industry reorganisation in the early 1970s saw changes to UKAEA’s structure and role and after a rapid expansion in the subsequent years, the UKAEA became a key employer in the region, boosting a workforce of 4,500 through the civil nuclear programme. The expansion significantly impacted the communities surrounding the site we now know as Birchwood Park, with towns such as Sellafield in Cumbria and Dounreay in the Scottish Highlands experiencing booms in population, as people were in search for employment opportunities in the local area. Alongside the UKAEA, other privatised companies working in nuclear construction and operation, were able to provide secure jobs and competitive salaries. In 1975, a Prototype Fast Reactor (PFR) situated in Dounreay commenced operation[5] and as a result, the local area saw a newfound economic prosperity, leading to thriving towns with an abundance of new amenities.
Evolution and transformation
The next twenty years saw an influx of activity, ushering an era of transformation for the nuclear industry in the UK. Political shifts and changing public sentiment around nuclear energy drove an initial decline within the nuclear community in the 1980s. The initial optimism surrounding nuclear as a clean power source began to decline and the positive public sentiment started to disappear following economic downturns and the infamous Chernobyl disaster in the late 1980s.
The UKAEA’s research and development across the entire fuel cycle came to a standstill and reactor safety and waste management were prioritised instead. The Protype Fast Reactor (PFR) at Dounreay ceased operation following the result of a Government policy decision not to procced further with fast reactor research. Reflecting on the growing negative sentiment around nuclear energy, focus completely shifted towards maximising outputs from existing reactors in the UK ensuring safe practices and the prevention of a nuclear disaster.[6]
The UKAEA faced yet another significant change, with the government privatising of some of their commercial functions[7], in their efforts to streamline operations across the industry. In effect, the decentralisation allowed for a more market driven nuclear sector in the UK, with private companies competing for contracts and driving an innovative and collaborative field. Recognising the established infrastructure around the Birchwood Park area, the privatisation process saw an inflow of new companies around the site. From waste decommissioning organisations to nuclear engineering consultancies, businesses working in the nuclear industry were building headquarters and maximising their efforts and expertise through creating a diverse nuclear ecosystem in the area.
Despite initial scepticism in the industry, the Park’s position as a leading hub for nuclear research and development became apparent in the 1990s, further transformation of the UKAEA’s research facility saw the landmark decision to create a dedicated business destination and in 1998, Birchwood Park was established[8]. Boasting significant advantages to companies working within the nuclear industry, the site was able to leverage the legacy of the UKAEA’s research programmes and the presence of a highly skilled and collaborative workforce. Furthermore, The Park’s established infrastructure and specialised laboratories offered a cost-effective solution for those operating in the field.
The ongoing evolution of the nuclear sector continued into the 21st century with a more measured approach. The establishment of Birchwood Park paves the way for a more dynamic and growingly competitive industry, working towards similar objectives. Solidifying its role as a world-class nuclear cluster, The Park continues to play a pivotal role in the UK nuclear scene, working towards a net zero future.
Innovation in Nuclear
Pioneering Small Modular Reactors
Creating innovative and fit for purpose solutions, occupiers on Birchwood Park play a fundamental role in the manufacturing process of Small Modular Reactors (SMR) across the UK. In comparison to traditional large-scale nuclear reactors, SMR designs are simpler and easy to manufacture.[9] Designed to be smaller and more modular than other reactors, SMRs boast an array of advantages, including:
Flexibility and scalability: Due to the smaller size of these reactors, SMRs can be deployed modularly, allowing for gradual increases in power generation if needed. As SMRs are easier to transport, they are ideal for remote locations with a limited grid infrastructure, the flexibility of these reactors also allow for accompanying existing power sources with cleaner, recyclable energy. The off-site factory build reduces costs, with easier transportation and shorter assembly and construction times.
Future Focused: Minimising waste generation and construction footprints, the streamline design of SMRs have a reduced environmental impact. These compact power stations offer tangible benefits which include mitigating climate change through zero greenhouse gas emissions and stimulating economic growth through significant job creation.[10] SMR developments directly contribute to responsible practices within the industry. By maintaining high safety standards, flexibility and offering many benefits for the future, SMRs offer a compelling alternative to larger reactors, promoting responsible clean energy through a variety of safety features.
Nuclear AMRC
Operating across nuclear new build, operations, decommissioning and technology development, and in other high-value low-carbon manufacturing industries, the Nuclear Advanced Manufacturing Research Centre (Nuclear AMRC) is led by industry experts to help UK companies secure work across the nuclear sector. Working closely with industry partners, the UK government and academic institutions, the Nuclear AMRC opened its first facility in Rotherham in 2012 as a central hub for research and development in the nuclear field.
Birchwood Park occupier, Jacobs joined the Nuclear AMRC as a member in August 2021 to help drive innovation in advanced nuclear technologies. As part of its membership, Jacobs provides the centre with engineering and office space at its facility on Bridgewater Place, giving the Nuclear AMRC a presence at the heart of the UK’s largest nuclear region.
Collaborating with companies to develop innovative techniques and optimised processes for large-scale high-precision manufacturing, Nuclear AMRC’s key capabilities lie within areas that are vital for modern nuclear manufacturing. Building on its established expertise in large-scale machining, joining, inspection and non-destructive testing, the centre is now expanding its capabilities in areas including digital engineering, additive manufacturing, controls and instrumentation, and manufacturing engineering.
Work at the Birchwood Park facility has focused on modular manufacturing, developing specialised techniques for the off-site modular production, assembly and maintenance of complex systems, to support technology developers in a variety of small modular reactor (SMR) and advanced modular reactor (AMR) programmes.
Though modular techniques are widely used in other safety-critical industries such as aerospace and shipbuilding, modular manufacturing can significantly reduce construction risk and help deliver new power stations to schedule and cost in the nuclear sector. There are many advantages of modular manufacturing within the nuclear industry, including improved efficiency by streamlining the construction process and enhanced quality control with prefabrication in controlled environments, reducing the risk of construction errors.
The Nuclear AMRC’s systematic approach to the modularisation of complex assemblies has enabled the organisation to develop a through-life modularisation product structure, which can be used in the early design process and provide benefits throughout its service life. By considering factors such as design style, modules boundaries, interfacing methods and the degree of modularity required, risks can be reduced in manufacturing and construction, whilst simplifying operations from installation to decommissioning.
Cavendish Nuclear
Cavendish Nuclear, a wholly-owned subsidiary of Babcock International Group, provide a comprehensive range of critical nuclear solutions across the markets of Clean Energy, Defence and Civil Decommissioning, both in the UK and internationally[11]. From decommissioning redundant nuclear facilities, to supporting the operation and build of nuclear power plants, the company plays a vital role cleaning up the nuclear legacy, with the aim to create a world where nuclear plays a key contribution in protecting the nation, ensuring security of energy supply and meeting the UK’s net zero commitments.
Nuclear has a critical role in delivering net zero by 2050, and clean energy is a core focus for Cavendish Nuclear through their support to existing reactors, the construction of Hinkley Point C and Sizewell C, and the work to develop advanced nuclear technologies for the future. Cavendish Nuclear supports EDF Energy in the operation of their nuclear reactor fleet and are part of the MEH Alliance at Hinkley Point C delivering all of the main mechanical, electrical, heating (MEH) and ventilation works for the UK’s first new nuclear power station in two decades. With interests across the wider clean energy market including Small Modular Reactors (SMRs), Cavendish Nuclear is also supporting X-energy as their UK Advanced Modular Reactor (AMR) deployment partner.
In Defence and Civil Decommissioning Cavendish Nuclear play a leading role in the integration and delivery of complex engineering projects. Their capability and experience in the complete decommissioning of nuclear related infrastructure, associated facilities and equipment allows them to provide fully integrated solutions that can be delivered in-house for both UK and international customers.
Looking ahead: Building a sustainable future together
Birchwood Park’s history is a true testament to the dynamic nature of the nuclear industry. From its wartime origins to its current role as a global hub for cutting-edge technologies, the Park has consistently served as a central catalyst for innovation. As we enter a pivotal point in the UK’s nuclear revival, commitment to fostering dynamic and innovative environments is fundamental in tackling complex challenges while accelerating technological advancements in the nuclear industry.
As clean energy holds significant promise in achieving global sustainability goals, Birchwood Park’s commitment to the industry and its efforts for Net Zero is increasingly recognised, as the Park is poised to remain a global leader in the nuclear sector. Its continued success will be vital in ensuring a safe, sustainable, and secure future powered by clean nuclear energy.
[2] Norman Bird: Risley Site Timeline
[7] Grahame Danby: House of Commons Library
