Quick Overview
- 1#1: METSIM - METSIM delivers comprehensive steady-state and dynamic simulation for mineral processing and metallurgical plants.
- 2#2: SysCAD - SysCAD provides advanced dynamic process modeling and simulation tailored for mining and mineral processing operations.
- 3#3: JKSimMet - JKSimMet offers full-featured simulation of grinding, classification, flotation, and dewatering circuits in mineral processing.
- 4#4: USIM PAC - USIM PAC enables accurate mass balancing, modeling, and optimization of mineral processing plants.
- 5#5: LIMN - LIMN facilitates detailed flowsheet modeling and economic analysis for mineral processing circuits.
- 6#6: HSC Chemistry - HSC Chemistry performs equilibrium-based process simulations and database-driven mineral processing calculations.
- 7#7: AggFlow - AggFlow simulates crushing, screening, and conveying operations in aggregate and mineral processing plants.
- 8#8: Aspen Plus - Aspen Plus supports rigorous process simulation for hydrometallurgical and mineral processing flowsheets.
- 9#9: COMSOL Multiphysics - COMSOL Multiphysics models coupled physics phenomena in mineral processing equipment and reactors.
- 10#10: Ansys - Ansys delivers CFD and FEA simulations for optimizing mineral processing unit operations like flotation and leaching.
Tools were prioritized based on technical robustness, user-friendliness, real-world performance, and alignment with critical mineral processing needs such as simulation accuracy, circuit optimization, and cost modeling.
Comparison Table
Mineral processing software is essential for streamlining operations and improving outcomes in mining and materials processing. This comparison table examines key tools like METSIM, SysCAD, JKSimMet, USIM PAC, LIMN and more, outlining their core features, use cases, and performance metrics. Readers will gain clarity to select the most suitable software for their specific project needs, from simulation to design and optimization.
| # | Tool | Category | Overall | Features | Ease of Use | Value |
|---|---|---|---|---|---|---|
| 1 | METSIM METSIM delivers comprehensive steady-state and dynamic simulation for mineral processing and metallurgical plants. | specialized | 9.8/10 | 9.9/10 | 8.4/10 | 9.3/10 |
| 2 | SysCAD SysCAD provides advanced dynamic process modeling and simulation tailored for mining and mineral processing operations. | specialized | 9.2/10 | 9.6/10 | 7.9/10 | 8.8/10 |
| 3 | JKSimMet JKSimMet offers full-featured simulation of grinding, classification, flotation, and dewatering circuits in mineral processing. | specialized | 8.5/10 | 9.2/10 | 8.0/10 | 8.3/10 |
| 4 | USIM PAC USIM PAC enables accurate mass balancing, modeling, and optimization of mineral processing plants. | specialized | 8.2/10 | 8.7/10 | 7.5/10 | 8.0/10 |
| 5 | LIMN LIMN facilitates detailed flowsheet modeling and economic analysis for mineral processing circuits. | specialized | 8.2/10 | 9.1/10 | 6.8/10 | 8.0/10 |
| 6 | HSC Chemistry HSC Chemistry performs equilibrium-based process simulations and database-driven mineral processing calculations. | specialized | 7.8/10 | 8.5/10 | 7.0/10 | 7.2/10 |
| 7 | AggFlow AggFlow simulates crushing, screening, and conveying operations in aggregate and mineral processing plants. | specialized | 8.4/10 | 9.1/10 | 7.8/10 | 8.0/10 |
| 8 | Aspen Plus Aspen Plus supports rigorous process simulation for hydrometallurgical and mineral processing flowsheets. | enterprise | 7.8/10 | 8.5/10 | 6.2/10 | 7.0/10 |
| 9 | COMSOL Multiphysics COMSOL Multiphysics models coupled physics phenomena in mineral processing equipment and reactors. | enterprise | 7.8/10 | 9.2/10 | 5.1/10 | 6.4/10 |
| 10 | Ansys Ansys delivers CFD and FEA simulations for optimizing mineral processing unit operations like flotation and leaching. | enterprise | 6.8/10 | 8.0/10 | 4.5/10 | 5.5/10 |
METSIM delivers comprehensive steady-state and dynamic simulation for mineral processing and metallurgical plants.
SysCAD provides advanced dynamic process modeling and simulation tailored for mining and mineral processing operations.
JKSimMet offers full-featured simulation of grinding, classification, flotation, and dewatering circuits in mineral processing.
USIM PAC enables accurate mass balancing, modeling, and optimization of mineral processing plants.
LIMN facilitates detailed flowsheet modeling and economic analysis for mineral processing circuits.
HSC Chemistry performs equilibrium-based process simulations and database-driven mineral processing calculations.
AggFlow simulates crushing, screening, and conveying operations in aggregate and mineral processing plants.
Aspen Plus supports rigorous process simulation for hydrometallurgical and mineral processing flowsheets.
COMSOL Multiphysics models coupled physics phenomena in mineral processing equipment and reactors.
Ansys delivers CFD and FEA simulations for optimizing mineral processing unit operations like flotation and leaching.
METSIM
specializedMETSIM delivers comprehensive steady-state and dynamic simulation for mineral processing and metallurgical plants.
Its proprietary METSIM database with thousands of minerals, compounds, and reactions, enabling highly accurate simulations without extensive user-defined data input
METSIM is a premier steady-state process simulation software designed specifically for the mineral processing and metallurgical industries, allowing users to model complex flowsheets with rigorous mass, energy, and component balances. It supports a wide range of unit operations from crushing and grinding to leaching, flotation, smelting, and refining, with specialized modules for hydrometallurgy, pyrometallurgy, and electrometallurgy. Widely used by major mining companies, METSIM excels in optimizing plant performance, troubleshooting issues, and evaluating process alternatives through accurate, industry-validated simulations.
Pros
- Comprehensive library of over 300 unit operations tailored to mineral processing
- Exceptionally accurate mass/energy balance solvers with extensive thermodynamic database
- Modular architecture allowing customization and integration with Excel, MATLAB, and other tools
Cons
- Steep learning curve due to its depth and complexity
- Primarily Windows-based with limited cross-platform support
- High upfront licensing costs may deter smaller operations
Best For
Large-scale mining and mineral processing companies needing precise, enterprise-grade steady-state simulations for plant design, optimization, and debottlenecking.
Pricing
Modular perpetual licenses starting at approximately $20,000 for the base package, with additional modules from $5,000-$15,000 each; annual maintenance fees around 15-20% of license cost required for updates and support.
SysCAD
specializedSysCAD provides advanced dynamic process modeling and simulation tailored for mining and mineral processing operations.
Advanced dynamic simulation engine with real-time control and optimization for testing process strategies under varying conditions
SysCAD is a comprehensive steady-state and dynamic process simulation software tailored for the minerals processing, metallurgy, and hydrometallurgy industries. It enables users to model complex flowsheets with rigorous mass, energy, and species balances, incorporating extensive databases for minerals, electrolytes, and reactions. The software supports custom unit operations, reactors, and advanced features like ProBal for data reconciliation and dynamic control systems.
Pros
- Extensive library of mineral processing unit operations and species databases
- Seamless integration of steady-state and dynamic simulations for process optimization
- Highly customizable with user-defined models and scripting capabilities
Cons
- Steep learning curve, especially for dynamic modeling and customization
- High licensing costs unsuitable for small teams or individuals
- Resource-intensive for very large-scale simulations
Best For
Process engineers and metallurgists in large-scale mining and mineral processing operations needing advanced dynamic flowsheet simulations.
Pricing
Perpetual licenses start at approximately $15,000-$30,000 depending on modules, plus annual maintenance fees; volume discounts and custom quotes available.
JKSimMet
specializedJKSimMet offers full-featured simulation of grinding, classification, flotation, and dewatering circuits in mineral processing.
Its rigorously tested, proprietary model library calibrated against decades of industrial data for unmatched accuracy in mineral processing simulations
JKSimMet is a comprehensive steady-state simulation software developed by CRC ORE for modeling mineral processing plants, covering unit operations from comminution and classification to flotation, leaching, and tailings management. It enables engineers to design flowsheets, perform mass and energy balances, optimize circuits, and troubleshoot operations using a validated library of over 40 models. Widely used in the mining industry for plant design, debottlenecking, and training, it integrates seamlessly with JKTech's other tools like JKSimFloat for advanced flotation modeling.
Pros
- Extensive library of industry-validated models for accurate steady-state simulations
- Intuitive graphical flowsheet builder with powerful mass balancing tools
- Proven track record in real-world plant optimization and academic training
Cons
- Primarily steady-state; dynamic simulations require separate JKSimDynamics software
- Learning curve for advanced model calibration and customization
- Limited native support for real-time data integration or machine learning features
Best For
Experienced mineral processing engineers focused on steady-state flowsheet design, optimization, and troubleshooting in comminution, flotation, and hydrometallurgy circuits.
Pricing
Enterprise licensing starts at custom quotes (typically $10,000+ annually per seat); academic and training versions available at reduced rates via CRC ORE.
USIM PAC
specializedUSIM PAC enables accurate mass balancing, modeling, and optimization of mineral processing plants.
Rigorous multicomponent mass balancing with built-in data reconciliation from plant and lab data
USIM PAC, developed by Caspeo, is a steady-state process simulation software tailored for the mineral processing sector, enabling detailed modeling of operations like crushing, grinding, flotation, leaching, and hydrometallurgy. It performs rigorous mass and energy balances, equipment sizing, and process optimization to support plant design, debottlenecking, and performance evaluation. With a focus on multicomponent, multiphase systems, it integrates laboratory and operational data for accurate simulations.
Pros
- Exceptional mass and energy balancing for complex mineral circuits
- Extensive library of unit operations specific to minerals processing
- Strong data reconciliation and uncertainty analysis tools
Cons
- Steep learning curve for non-expert users
- Limited support for dynamic simulations compared to competitors
- Pricing lacks transparency and can be high for smaller operations
Best For
Experienced mineral processing engineers and plant managers needing precise steady-state modeling for design and optimization.
Pricing
Custom enterprise licensing; typically starts at several thousand euros annually, with quotes based on modules and users.
LIMN
specializedLIMN facilitates detailed flowsheet modeling and economic analysis for mineral processing circuits.
Advanced data reconciliation engine that automatically detects and adjusts outliers while providing balance uncertainty estimates
LIMN is a specialized desktop software for mineral processing, focusing on flowsheet modeling, mass and metallurgical balancing, and data reconciliation. It allows engineers to build detailed plant models, reconcile assay and production data from surveys, and simulate process changes for optimization. Widely used in the industry for accurate reporting and troubleshooting, it supports multi-component systems and integrates with Excel for data handling.
Pros
- Powerful mass balancing and data reconciliation algorithms handle complex, real-world plant data effectively
- Supports large-scale flowsheets with multi-element assays and production reporting
- Proven reliability in mining operations with decades of industry use
Cons
- Outdated graphical user interface feels clunky compared to modern software
- Steep learning curve requires metallurgical expertise and training
- Windows-only, with limited cloud or mobile integration
Best For
Experienced mineral processing engineers in operating plants needing precise mass balancing and survey reconciliation.
Pricing
Custom quotes for perpetual or annual licenses; typically starts at $5,000+ for single-user professional editions.
HSC Chemistry
specializedHSC Chemistry performs equilibrium-based process simulations and database-driven mineral processing calculations.
Integrated mineral database enabling detailed liberation, association, and size-by-size mineralogical analysis
HSC Chemistry, developed by Metso, is a specialized software suite for thermodynamic modeling, chemical equilibrium calculations, and mineralogical analysis in mineral processing and metallurgy. It provides tools for phase diagrams, speciation, heat balance, and limited process flowsheeting, with a vast database of over 20,000 chemical species. Primarily used for research, process design, and optimization in hydrometallurgy and pyrometallurgy, it excels in static equilibrium simulations but lacks advanced dynamic or full-plant flowsheet capabilities compared to dedicated mineral processing simulators.
Pros
- Extensive thermochemical database with 20,000+ species
- Powerful equilibrium solvers like ChemSage for complex reactions
- Mineralogical tools for liberation and association analysis
Cons
- Steep learning curve for non-experts
- Limited support for dynamic simulations and full comminution/flotation modeling
- High licensing costs without modular pricing transparency
Best For
Metallurgical engineers and researchers needing precise chemical equilibrium and thermodynamic modeling for mineral extraction processes.
Pricing
Commercial perpetual or annual licenses starting at $5,000+ per seat; contact Metso for quotes, with modular add-ons available.
AggFlow
specializedAggFlow simulates crushing, screening, and conveying operations in aggregate and mineral processing plants.
Advanced dynamic flowsheet simulation that accurately models blended products, recirculating loads, and stockpile management unique to aggregate operations
AggFlow is specialized simulation software for modeling and optimizing aggregate processing plants, including crushing, screening, washing, and material handling operations. It enables users to predict plant performance, balance material flows, and generate production reports to improve efficiency and profitability in quarries and gravel pits. Primarily targeted at the aggregates industry, it supports design, troubleshooting, and daily operations with a comprehensive equipment library.
Pros
- Highly accurate plant flow simulations with detailed material balance calculations
- Extensive library of aggregate-specific equipment and process models
- Strong reporting tools for production forecasting and optimization insights
Cons
- Limited applicability beyond aggregates to broader mineral processing like ore beneficiation
- Interface feels dated and has a moderate learning curve for new users
- Requires significant data input for precise modeling
Best For
Quarry and aggregate producers seeking to simulate and optimize crushing/screening plants for maximum throughput and product quality.
Pricing
Subscription-based; annual licenses start around $4,000-$6,000 depending on modules and users, with custom enterprise pricing available.
Aspen Plus
enterpriseAspen Plus supports rigorous process simulation for hydrometallurgical and mineral processing flowsheets.
Electrolyte Wizard for precise thermodynamic modeling of complex aqueous systems in leaching and solvent extraction
Aspen Plus, developed by AspenTech, is a comprehensive steady-state process simulation software primarily designed for chemical and process industries, with capabilities extending to mineral processing through solids handling, electrolyte thermodynamics, and unit operations like leaching, crystallization, and separation. It enables detailed modeling of hydrometallurgical and pyrometallurgical processes, optimization of flowsheets, and economic analysis for minerals extraction and refining. While versatile, it requires customization for specialized mineral circuits like flotation or grinding.
Pros
- Extensive thermodynamic databank including electrolytes and minerals for accurate hydrometallurgy simulations
- Powerful optimization and sensitivity tools for process design and debottlenecking
- Robust solids modeling with particle size distributions and custom unit operations
Cons
- Steep learning curve, especially for mineral engineers without chemical process background
- High enterprise-level cost with no public pricing
- Limited built-in templates for dynamic mineral processing like flotation kinetics compared to specialized tools
Best For
Experienced process engineers in large mining operations needing advanced steady-state simulation and optimization for hydrometallurgical flowsheets.
Pricing
Enterprise subscription licensing; contact AspenTech for quote, typically $20,000+ annually per seat depending on modules and users.
COMSOL Multiphysics
enterpriseCOMSOL Multiphysics models coupled physics phenomena in mineral processing equipment and reactors.
Seamless multiphysics coupling that allows simultaneous simulation of fluid dynamics, chemical kinetics, and particle transport in mineral processing equipment like flotation cells or thickeners.
COMSOL Multiphysics is a general-purpose finite element analysis software that excels in multiphysics simulations, enabling modeling of mineral processing phenomena like slurry flows, flotation dynamics, particle separation, leaching reactions, and heat/mass transfer in comminution processes. Users can couple modules such as CFD, particle tracing, chemical reaction engineering, and porous media flow to create custom models tailored to specific mineral processing challenges. While highly powerful for research and advanced engineering, it requires significant setup effort as it is not pre-configured for standard mineral processing workflows.
Pros
- Unmatched flexibility in coupling multiphysics like fluid-particle interactions and geochemistry
- High-fidelity simulations validated against experimental data in mineral processing applications
- Extensive library of physics interfaces and solver capabilities for complex, nonlinear problems
Cons
- Steep learning curve requiring FEM expertise to build mineral processing models from scratch
- Prohibitively expensive for small teams or routine operations
- Lacks industry-specific templates or workflows compared to dedicated mineral processing tools
Best For
Research engineers and PhD-level modelers in mineral processing R&D who require bespoke multiphysics simulations for novel processes.
Pricing
Modular annual subscriptions start at ~$4,000-$10,000 per user for core modules, scaling to $20,000+ for full multiphysics suites with mineral processing-relevant add-ons; academic discounts available.
Ansys
enterpriseAnsys delivers CFD and FEA simulations for optimizing mineral processing unit operations like flotation and leaching.
CFD-DEM coupling for realistic simulation of multiphase slurry flows in mills and separators
Ansys is a comprehensive multiphysics simulation platform that can be applied to mineral processing for modeling fluid dynamics, particle flows, and structural integrity in equipment like mills, hydrocyclones, and flotation cells. It leverages tools such as Fluent for CFD and Rocky for DEM to simulate complex processes including comminution, slurry transport, and separation. While powerful for custom engineering simulations, it lacks built-in mineral-specific modules or mass balancing tools found in dedicated software.
Pros
- Powerful CFD and DEM simulations for accurate particle-fluid interactions in processes like grinding and classification
- Multiphysics coupling for integrated analysis of mechanical, thermal, and flow behaviors
- Validated models and extensive customization for research-grade mineral processing studies
Cons
- Steep learning curve requiring specialized engineering expertise
- No native support for mineral processing workflows like circuit balancing or flotation kinetics
- High cost unsuitable for small-scale or routine operations
Best For
Large mining companies or research institutions with expert simulation teams needing high-fidelity custom modeling for equipment optimization.
Pricing
Enterprise subscription licensing; pricing upon request, typically $10,000+ annually per user for commercial modules.
Conclusion
This review showcases the variety of solutions in mineral processing software, with METSIM leading as the top pick for its wide-ranging steady-state and dynamic simulation capabilities. SysCAD impresses with advanced dynamic modeling for mining operations, while JKSimMet excels in detailed simulations of critical circuits like grinding and flotation—each offering distinct strengths to suit different operational needs. These tools collectively elevate efficiency in mineral processing workflows.
Explore METSIM to experience its comprehensive simulation power and start optimizing your mineral processing operations today.
Tools Reviewed
All tools were independently evaluated for this comparison