Stern Laboratories Inc. – Hamilton, Ontario, Canada

October 31, 2024

Stern Laboratories Inc.

Spearheading the Future of Nuclear Innovation

Expertly blending cutting-edge research, strategic global partnerships, and a forward-thinking approach to nuclear energy

Stern Laboratories Inc. is a powerhouse in the thermal-hydraulics research sector, boasting a staggering 49,000 square feet of laboratory space. This expansion, recently increased by 10,000 square feet, speaks volumes about the scale and capabilities of the operation. President Gordon Hadaller underlines the facility’s capacity, detailing how the lab functions at full scale with water-cooled reactor pressures and temperatures. “We have 17MW of D.C. power,” he notes, a feature that sets Stern Labs apart as one of the most extensive facilities of its kind in North America.

The lab is not just a national asset but pivotal in servicing the global water reactor industry. Stern Labs’ reach extends to CANDU plants across Canada, Korea, and China, as well as to the Boiling Water Reactor (BWR) and Pressurized Water Reactor (PWR) industries throughout North America, Asia and Europe. This expansive network illustrates the lab’s international influence and expertise. Hadaller elaborates, “We service the worldwide water reactor industry,” positioning Stern Labs as a central player in the global nuclear landscape.

Moreover, the lab’s scope goes beyond research. It provides specialty fuel simulators and intricate electric heaters that mimic fuel pins. Hadaller says, “We have a department that does this custom design and manufacturing for these projects.” This specialization in custom tooling for the nuclear industry indicates the lab’s ability to deliver tailored solutions, catering to each client’s unique needs.

The Case for Nuclear in a Diversified Energy Mix

The debate over the most effective and reliable sources intensifies as the world pivots toward renewable energy. Hadaller is candid about the limitations of various renewable sources, noting, “I think we need to use all forms of clean energy.” He acknowledges the potential of solar and wind but points out their inherent drawbacks, particularly in regions like Ontario.

Solar power, while beneficial in many respects, struggles with a low-capacity factor in areas that experience significant cloud cover. “In Ontario, we have a lot of clouds. It isn’t a really great place for solar,” he remarks. Similarly, wind power, though valuable, suffers from intermittency issues. “Wind tends to be very intermittent and often blows at night when you don’t need the power,” he says, highlighting the need for storage solutions or backup systems to compensate for its unpredictable nature.

Hadaller outlines nuclear energy’s key advantages, emphasizing its steady, inflation-proof power. While nuclear plants have high initial costs, their operational expenses are low. “If you build a plant and run it for 30 years, you’re going to get your money back,” he says, highlighting nuclear power’s long-term economic stability compared to other energy sources. Ontario is a prime example: “The grid…is about 60% nuclear and runs 24/7,” providing a reliable energy baseload, unlike intermittent sources like solar and wind.

Hadaller also mentions nuclear safety, noting that much of Stern Labs’ work supports maintaining robust safety margins. While he acknowledges the value of hydropower, he points out its limitations: “We’ve run out of rivers to dam up.” Thus, he views nuclear as essential for a balanced energy grid. He is optimistic about Small Modular Reactors (SMRs), such as Ontario’s BWRX-300. He believes “they should be cost competitive” if economies of scale are achieved.

Pivotal Moments and Steady Growth

Stern Laboratories’ journey from a division of a corporate giant to an independent, employee-owned entity marks a significant chapter in the company’s history. “When we became a private company, that opened the market up,” Hadaller explains. Previously limited to serving Westinghouse Canada and the Canadian CANDU industry, Stern Labs found itself free to work with a broader array of nuclear suppliers. This newfound independence allowed the lab to carve out a niche in the global nuclear research industry.

Another critical milestone came in 1991 when Ontario Hydro awarded Stern Labs a full-scale CANDU Critical Heat Flux (CHF) test contract. “We added 12.5MW of D.C. power to our power system,” Hadaller recalls. This enhancement enabled the lab to conduct full-scale testing for CANDU reactors, Boiling Water Reactors (BWR), and Pressurized Water Reactors (PWR). This leap in capability significantly broadened the lab’s scope and cemented its position as a leader in thermal-hydraulics research.

Stern Labs’ steady growth aligns with industry needs and technological advancements. In 2002, the lab expanded significantly when a major BWR fuel vendor transferred its work to Stern Labs. “We’ve been their supplier of choice since then,” Hadaller notes. Recently, they added 10,000 square feet to their facility, now totaling 49,000 square feet, signaling readiness for future projects. “When I have new customers… we can say, well, here’s a spot we have for you,” he says, highlighting their expanded capacity.

Projects Manager Richard Van Lochem emphasizes that continual infrastructure upgrades, such as waterjet and machine use, have been vital to maintaining competitiveness. Stern Labs also explores new technologies, including additive manufacturing and fiber optics for temperature measurement. “We’re always trying to keep up with what are the new technologies,” he states. Investment in tools like orbital welders has provided “finer controls” in the company’s operations.

International Collaborations and Cutting-Edge Projects

Stern Laboratories has been at the forefront of developing innovative solutions for the nuclear industry, engaging in projects that span the globe and push the boundaries of reactor technology.

Stern Labs is actively engaged in international projects, supporting clients in Asia, Italy, Sweden, South Korea, and Canada. They aid in developing advanced fuel elements with enhanced performance, as Van Lochem notes, “The heater rods are getting smaller. There’s more instrumentation, different types of instrumentation.”

In CANDU reactor projects, Stern Labs works on innovative tooling, such as camera systems for fuel inspection and removal systems for radioactive flux detectors.” We’re engaged with some CANDU operators to develop new innovative tooling,” Van Lochem says.

The lab’s international reach includes building a scaled reactor mock-up in Italy and negotiations with a Swedish SMR designer exploring lead as a coolant. “There’s ongoing negotiations… looking to use lead for their coolant,” Van Lochem adds. In South Korea, Stern Labs is working with a vendor on a new fuel design through “full-scale critical heat flux testing with a variety of different axial flux shapes,” demonstrating the lab’s expertise in complex nuclear technologies.

The Inflation Reduction Act’s Ripple Effect on Nuclear Research

The passage of the Inflation Reduction Act (IRA) in the United States has significantly influenced the nuclear research landscape, providing a much-needed boost to universities and research institutions engaged in advancing nuclear technology. Van Lochem outlines the act’s immediate benefits for the universities and research facilities with which Stern Labs collaborates.

“It certainly assists with a lot of the university and research facilities that we work with,” he states. The IRA enables these institutions to embark on new test programs, explore novel techniques, and experiment with advanced materials by providing additional funding. This support fosters an environment where innovation can thrive. Van Lochem lists some of the institutions involved, such as the University of Wisconsin, Oregon State, and Idaho National Labs, highlighting the breadth of the lab’s engagement in academic research.

Hadaller echoes this sentiment, noting a clear shift in university purchasing power post-IRA. “We’ve had universities… say, I don’t have much of a budget, but can you give me a price for 1 or 2 fuel simulators,” he recalls. However, after the IRA, “they come back… and say, I now have a budget, I want to order eight of these.” This increased funding has boosted R&D and signaled reactor vendors’ renewed focus to nuclear energy. The IRA also supports the life extension of nuclear reactors. Hadaller highlights, “There’s funding… to do life extensions on plants,” potentially preventing U.S. reactor shutdowns and promoting new reactor deployment.

Upgrading Infrastructure and Expanding Capacity

Stern Laboratories’ focus extends beyond research and testing to encompass significant upgrades to its technological and physical infrastructure. “Everything ties into computers,” Hadaller states, emphasizing technology’s critical role in the lab’s operations. One significant investment area is computational fluid dynamics (CFD), a vital tool for simulating and analyzing flow fields within nuclear fuel assemblies. “We’re trying to develop that technology because of some of the experiments we do,” he explains. The extensive data Stern Labs collects from various experiments is a valuable resource for verifying CFD models, ensuring they are accurate and reliable when applied to nuclear fuel assemblies.

Stern Labs is adopting machine learning to analyze extensive data on fuel assembly behavior. “We’re applying machine learning… to help do better correlations and also predict improvements in fuel design,” Hadaller states, aiming to refine predictions and advance fuel designs. Alongside technological upgrades, their administrative systems are being modernized to support an increasing workload.

The lab is also expanding its workforce to keep pace with growing contracts, especially as many older employees have retired. “We need to bring in more young people, especially with business prospects looking up,” Hadaller notes. The lab, built in 1948, requires refurbishment of electrical systems and cranes. “Some of the electrical systems… need to be replenished and refurbished,” Hadaller explains. These upgrades ensure the facility’s core operations remain efficient, supporting the lab’s expanding scope and future projects.

Collaboration with Industry Leaders

Collaboration is at the core of Stern Laboratories’ operations, enabling the lab to work closely with key players in the nuclear industry. These partnerships facilitate a rich exchange of expertise and resources, bolstering the lab’s role in advancing nuclear technology. Hadaller provides insight into the various public and private partners that Stern Labs engages with, highlighting the lab’s collaborative approach to innovation and development.

“We work with the CANDU Owners Group,” he shares, referring to the collective of CANDU reactor operators. This partnership is vital for sharing experimental results and operational experiences among CANDU utilities. By conducting research directly for this group, Stern Labs helps disseminate valuable knowledge that enhances the performance and safety of CANDU reactors worldwide. “This is a good way for the CANDU utilities to share experiments and experience,” Hadaller notes.

Stern Labs also maintains strong partnerships with major Canadian utilities like Ontario Power Generation, Bruce Power, and New Brunswick Power, focusing on optimizing CANDU reactor performance and safety. Internationally, Stern Labs collaborates with Global Nuclear Fuels (GNF), a G.E. subsidiary specializing in Boiling Water Reactor (BWR) fuel. Another critical partnership is with GE Hitachi. “We’re working with GE Hitachi on some of the deployment of the BWRX 300 in Darlington,” Hadaller mentions. This project advances Small Modular Reactors (SMRs), showing how Stern Labs is able to support nuclear technology development.

Priorities and Future Focus

Looking ahead, Stern Laboratories is poised for an intense period of project execution, innovation, and operational enhancement. The lab is gearing up to build numerous fuel simulators, requiring meticulous precision. These simulators are crucial for upcoming testing programs that will be more rigorous and comprehensive.

“We have some testing programs… with back-to-back testing on multiple configurations,” Hadaller explains, signaling sustained activity demanding Stern Labs’ total capacity. Innovation is critical, with new design work involving the development of loops and hardware for future projects. Hadaller emphasizes expanding the team and investing in talent. “Training is an important part of things,” he says regarding building a skilled workforce for an evolving industry.

Maintaining and enhancing the quality assurance system is another priority. Stern Labs undergoes regular customer audits to ensure protocols are up-to-date and reliable. Additionally, the lab relies on a network of suppliers, especially machine shops, for key components. Exploring new equipment like laser welders and additive manufacturing, Hadaller points out the potential benefits: “If you only need 20 or 30… additive manufacturing is certainly a very good option.”

As Stern Labs moves forward, its blend of executing large-scale projects, innovating in design and manufacturing, and maintaining stringent quality standards positions it as a key player in the nuclear research field. Hadaller’s priorities portray a strategic approach to growth, leveraging the lab’s expertise while continuously seeking ways to enhance and expand its capabilities. With an eye on the latest advancements while developing its team and processes, Stern Laboratories is well-equipped to tackle the challenges and opportunities that lie ahead.