SysCAD

What SysCAD does

SysCAD, operated by KWA Kenwalt Australia Pty Ltd and headquartered in Perth, is a niche process-plant simulation software vendor with origins in 1985 inside South Africa-based engineering firm Kenwalt. The product provides both steady-state and dynamic simulation across the full plant lifecycle — feasibility, design, commissioning, operations, and expansion — and is positioned as a digital-twin platform for mining, metallurgical, and chemical processing plants. The architecture is modular: a core SysCAD engine is extended by industry-specific add-ons (Alumina, Potash, Sugar, Met Dynamics for mineral processing, Energy) and by a Thermodynamic Calculation Engine (TCE) interface that integrates four third-party solvers — OLI, ChemApp/FactSage, AQSol, and PHREEQC — for high-fidelity phase-equilibrium and electrolyte chemistry. A Particle Size Distribution (PSD) add-on enables population balance modelling across comminution, flotation, precipitation, and tailings circuits.

The company monetises through annual enterprise subscription licences (with required upgrade and maintenance agreements) bundled with consulting/simulation services and training, supplemented by academic licensing and a self-serve trial download. Go-to-market combines enterprise direct sales, channel agents in Southern Africa (Ex Mente) and Chile (Promet101), and decades-long conference presence at ALTA, ICSOBA, AQW, and related industry events. Customers include Rio Tinto, BHP, Hatch, Worley, Jacobs, Orica, Tronox, Iluka, Mosaic, South32, and QUT among 150+ named enterprise and academic clients globally. The company is privately held, founder/management-owned, with 11-50 employees and no disclosed external funding.

Name

SysCAD

Legal name

KWA Kenwalt Australia Pty Ltd

Website

https://syscad.net

Company type

Private

Founded year

1985

Operating status

Operating

Headcount range

11–50 employees

Ownership category

akta.pro rank

Headquarters

HQ city

Perth

HQ country

Australia

HQ region

Oceania

Offices1 record

Markets served

GTM type

B2B

Offering type

Software

Cost components

Personnel, Technology or R&D, Operations, Marketing or Sales, Infrastructure

Revenue model

1. Software Licensing: SysCAD software is sold under flexible licensing models including various license options and add-ons (Alumina, Potash, PSD, TCE add-ons, Met Dynamics). Licenses include annual upgrade and maintenance agreements. The software transitioned from an in-house tool to a commercial product in the 1990s and is currently offered with flexible license options.
2. Consulting and Simulation Services: Provision of simulation and related process engineering services, including general and specialist modelling services, to clients alongside software sales.
3. Training Services: SysCAD provides training services to clients, both standard and in foreign languages (Spanish training delivered via agents). Training materials are translated and jointly delivered with regional agents.

Pricing tiers

Go-to-market motion3 records

Distribution channels4 records

Marketing channels6 records

Core offering

SysCAD is a process plant modelling and simulation software platform that supports both steady-state and dynamic simulation across the full plant lifecycle from feasibility studies through design, commissioning, operations, maintenance, and expansion. It functions as a digital twin platform with industry-specific add-ons for alumina (Bayer process), potash, sugar, and mineral processing, and integrates third-party thermodynamic calculation engines (AQSol, OLI, PHREEQC, ChemApp).

Product overview

SysCAD is a unified process simulation platform with a modular architecture. The core SysCAD product serves as the primary plant simulation engine, operating in both Steady State and Dynamic modes. Add-on modules extend the platform for specific industries: the Alumina Add-On for Bayer process simulation, Potash Add-On for MOP/SOP production, Sugar Add-On for cane sugar refining, and Met Dynamics Add-On for mineral processing. The Particle Size Distribution (PSD) Add-On enables population balance modelling across industries. Thermodynamic Calculation Engines (TCE) integrate third-party solvers (ChemApp, PHREEQC, AQSol, OLI) for rigorous thermodynamics. The Energy Add-On provides heat integration capabilities. The Digital Twin capability transforms steady-state models into dynamic operational twins.

Differentiator

Problem solved

Functional benefit

Products and services

• SysCAD Plant Simulation Software Core SysCAD platform for simulating processing circuits and complex full plant operations, operating as Steady State solver or Dynamic mode across the entire plant lifecycle from feasibility to expansion.
• SysCAD Alumina Add-On Specialized license option for steady-state and dynamic alumina refinery projects with Precipitation unit model for hydrate crystallisation and Bayer Properties model for thermodynamic liquor properties.
• SysCAD Potash Add-On Specialized add-on for muriate of potash (MOP) production with species model for MOP properties built on D'Ans (1952) solubility data, and phase change evaluation for KCl and NaCl precipitation/dissolution.
• SysCAD Met Dynamics Add-On Comprehensive library of PSD-enabled mineral processing models including comminution (mills, crushers, HPGR), classification (screens, hydrocyclones), and concentration (flotation cells, dense medium separators, gravity concentrators) models.
• SysCAD Particle Size Distribution (PSD) Add-On Population balance modelling add-on for tracking particle size distributions throughout comminution, flotation, heavy media separation, tailings, and product crystallisation circuits.
• SysCAD Sugar Add-On Dedicated Sugar industry add-on with industry-specific models for cane sugar refining, featuring neural network dynamic models for crystal growth prediction.
• SysCAD Energy Add-On Energy balance and heater sizing add-on for steam recovery in digestion circuits, integrates with Flash Train macro for energy integration analysis.
• SysCAD Thermodynamic Calculation Engines (TCE) Suite of third-party thermodynamic calculation engine interfaces including AQSol, OLI, PHREEQC, and ChemApp for rigorous phase equilibrium and solution property calculations in pyrometallurgy, hydrometallurgy, crystallisation, and water treatment.
• SysCAD Digital Twin Virtual representation of physical plant for simulating, predicting and optimising process operations; integrates with PIMS via open API; supports steady-state and dynamic plant-wide simulations.
• SysCAD Consulting Services Provision of simulation and related process engineering services, including general and specialist modelling services, to clients alongside software sales.
• SysCAD Training Services Standard and specialised training services delivered to clients, with foreign-language offerings (Spanish via Promet101 agent) for effective onboarding and capability development.

Quantifiable outcome

• 10% improvement in effectiveness predicted by Gartner for large industrial companies using digital twins
• +3 more outcomes

Named customers15 records

Segments7 records

Ideal customer profiles3 records

Technology focussed Yes

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Integration7 records

AI capability2 records

Feature12 records

Partnerships

Eight partnerships are on record, tiered core.

• HILT CRC (Heavy Industry Low-carbon Transition Cooperative Research Centre)coreStrategic or Co-development PartnerSysCAD joined HILT CRC as an Affiliate Partner in November 2024 to support decarbonisation pathways for alumina, iron/steel, and cement industries. SysCAD provides in-kind contributions annually including Full & Academic SysCAD Licenses, Comprehensive Training, and Support and Assistance Services. Key project ALUMINExt involves developing generic base case models for next-generation alumina refining technologies including energy recovery, net-zero steam generation, and calcination electrification.
• Met Dynamics (Scott Munro)coreStrategic or Co-development PartnerSysCAD collaborated with Scott Munro at Met Dynamics to develop the Met Dynamics Add-On for SysCAD, providing a comprehensive library of PSD-enabled process unit models for mineral processing (mills, crushers, screens, hydrocyclones, flotation cells, separators). The add-on extends SysCAD's capability as a single platform for detailed simulation across mineral processing, hydrometallurgy, pyrometallurgy, water treatment and utilities.
• Ex MentecoreChannel Partner/ Reseller/ DistributorEx Mente, based in Pretoria, South Africa, was appointed as the agent for SysCAD in Southern Africa in February 2020. Ex Mente has extensive relevant experience in simulation software and process engineering, specialising in pyrometallurgy, and provides support for SysCAD sales enquiries, services, and training across a range of industries.
• Promet101coreChannel Partner/ Reseller/ DistributorPromet101, based in Chile, is the agent for SysCAD in Chile. They translated SysCAD training materials to Spanish and jointly provided the first Spanish-language SysCAD training course in Santiago. Promet101 provides local support for SysCAD sales, services, and training in Chile and Latin America.
• OLI SystemscoreTechnology or IntegrationSysCAD is formally an OLI Alliance Partner. The OLI Engine in SysCAD allows the latest OLI databanks to be accessed from within the SysCAD flowsheet for more accurate simulation of processing steps involving electrolyte solutions. The SysCAD OLI Reactor unit model is configurable for aqueous solution applications including Neutralisation, pH control, Crystallisation, and Solubility. OLI licenses are required separately from OLI Systems.
• GTT-Technologies (ChemApp/FactSage)coreTechnology or IntegrationGTT-Technologies provides ChemApp, integrated via SysCAD's TCE interface for high-fidelity pyrometallurgical process simulation. Seven years of industrial experience with the SysCAD-ChemApp interface enables rigorous thermodynamics directly in steady-state and dynamic plant-wide process simulations. SysCAD auto-parallelises ChemApp calculations for fast plant-wide optimisation.
• Aqueous Solutions ApS (AQSol)coreTechnology or IntegrationAQSol provides thermodynamic phase equilibrium calculations for multi-component systems and concentrated electrolyte solution chemistry, integrated via SysCAD's TCE interface. Used for crystallisation and water treatment applications including lithium production modelling.
• U.S. Geological Survey (PHREEQC)coreTechnology or IntegrationPHREEQC, developed by USGS, is integrated via SysCAD's TCE interface for aqueous geochemical calculations, activity coefficient models, and surface complexation. Used in water treatment, tailings management, mineral salts, lithium, rare earths, and potash applications.

Scale indicators3 records

Recent moves11 records

Expansion highlights5 records

Direct peers

• KBC (Yokogawa): KBC, now part of Yokogawa, provides process simulation (PRO/II predecessor technologies) and digital twin solutions for refining, petrochemicals, and energy. Its Petro-SIM platform competes with SysCAD's hydrocarbon and chemical processing capabilities.
• Aspen Technology (AspenTech): AspenTech is the largest process simulation software vendor with Aspen Plus and Aspen HYSYS dominating chemical and petrochemical simulation. It competes directly with SysCAD in steady-state and dynamic process modeling for mining, metals, and chemical processing customers globally.
• ChemCAD: ChemCAD is a chemical process simulation suite used for steady-state and dynamic modeling of chemical plants. It targets similar engineering company and owner-operator customers as SysCAD in chemical processing applications.
• METSIM: METSIM is a specialized process simulation package for mineral and metallurgical processing, directly comparable to SysCAD's Met Dynamics Add-On and Alumina/Potash add-ons. It targets mining and metallurgical engineers for steady-state plant simulation.
• Honeywell UniSim: Honeywell's UniSim Design Suite competes directly with SysCAD in process simulation for refining, petrochemical, and natural gas processing. It overlaps with SysCAD's dynamic simulation and operator training simulator capabilities for heavy industrial process plants.
• ProMax: ProMax by Bryan Research & Engineering is a process simulation tool specialized in gas processing, amine treating, and refrigeration. It overlaps with SysCAD in process plant modeling for chemical and energy industries.
• AVEVA (PRO/II / SIMSCI): AVEVA's PRO/II (formerly SimSci) is a steady-state process simulator widely used in chemicals and refining. AVEVA competes with SysCAD in process modeling and increasingly in industrial digital twin offerings for plant operations.

Broad incumbents

• Dassault Systèmes (3DEXPERIENCE): Dassault Systèmes provides broad engineering and process simulation capabilities within its 3DEXPERIENCE platform, including process modeling for manufacturing and infrastructure. It competes with SysCAD at the enterprise platform level for industrial digital twin deployments.
• ANSYS: ANSYS provides multiphysics simulation software (Fluent, Mechanical, etc.) used in process industries for CFD and equipment-level analysis. It complements rather than directly replaces SysCAD for full-plant flowsheet simulation, but competes for engineering simulation budget.
• Siemens Simcenter (Hexagon): Siemens Simcenter (now part of Hexagon after the EDA divestiture) is a broad engineering simulation portfolio covering multiphysics, electronics, and system-level modeling. It overlaps with SysCAD at the system/process simulation level for industrial customers.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat6 records

Key risks7 records

Key highlights7 records

Customer concentration

• LinkedInlinkedin.com/company/syscad

Revenue estimate

Valuation estimate

Number of profiles

Profiles10 records

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about SysCAD