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This is a complete feature article on ChemCAD NXT , the latest evolution of the ChemCAD process simulation software suite, now offered by MST (Mohan’s Simulation Tech) .
ChemCAD NXT: The Rebirth of a Process Simulation Workhorse Introduction: A New Era for an Old Standard For over three decades, ChemCAD has been a staple in the engineering toolkits of chemical, petrochemical, and pharmaceutical companies. Originally developed by Chemstations, the software earned a reputation for its user-friendly interface, robust thermodynamic engine, and reasonable price point. In 2020, MST (Mohan’s Simulation Tech) acquired ChemCAD, rebranding it as ChemCAD NXT . This acquisition marked a pivotal shift: from a mature but slowly evolving tool to a modern, agile platform. "NXT" is not merely a version number; it represents a fundamental rewrite and re-architecture of the classic simulator for the 2020s. This feature explores the complete landscape of ChemCAD NXT—its architecture, core features, usability improvements, industry applications, and its strategic positioning against giants like Aspen HYSYS and AVEVA SimCentral.
Part 1: The Architecture – Legacy Code Meets Modern Stack The original ChemCAD was written in Fortran and C++. While computationally fast, its user interface (UI) and data handling were showing their age. ChemCAD NXT retains the proven thermodynamic and unit operation libraries (the "solver") but completely rebuilds the front-end and data management layer. Key Architectural Shifts: chemcad nxt
.NET Core / C# Front-End: The UI is now built on modern Microsoft frameworks, allowing for smoother graphics, high-DPI scaling, and native Windows 11 integration. 64-Bit Native Computation: Unlike older versions that were limited to 4GB of RAM, NXT can utilize terabytes of memory, enabling simulations of massive refinery complexes or detailed column hydraulics. SQLite Database Backend: Input data and results are stored in an open SQLite format. This allows engineers to query results directly using Python or Power BI without exporting CSV files. Multi-Threaded Solving: Dynamic solvers and distillation convergence routines now leverage multi-core processors, reducing simulation time for large flowsheets by 30-50%.
Part 2: Core Modeling Capabilities ChemCAD NXT covers the full spectrum of steady-state process simulation. It does not yet compete in the dynamic simulation space (like HYSYS Dynamics), but it excels in design and rating. Thermodynamics (The Heart of Any Simulator) NXT includes over 40 thermodynamic methods, including:
Equations of State: Soave-Redlich-Kwong (SRK), Peng-Robinson (PR), Lee-Kesler-Plöcker, and the advanced CPA (Cubic Plus Association) for hydrogen bonding systems. Activity Coefficient Models: NRTL, UNIQUAC, UNIFAC, Wilson, and Van Laar. Specialized Databases: Sour water (H2S/NH3/CO2), electrolyte systems (mixed-solvent electrolytes), and a pure component database of over 4,000 compounds. The system requirem
Unit Operation Library NXT includes over 60 unit operation models. The most notable are:
Distillation (SCDS – Simplified Continuous Distillation): The workhorse column model supports any number of stages, side draws, pumparounds, and complex condenser/reboiler configurations. Convergence is handled via the Boston-Sullivan method (robust for non-ideal systems). Reactors: Gibbs free energy minimizer (RGBS), stoichiometric (RSTOIC), equilibrium (REquil), CSTR, and plug flow reactor (RPlug) with kinetics. Heat Exchangers: Rigorous shell-and-tube rating (using HTRI or TASC interfaces), fired heaters, air coolers, and LNG-specific multi-stream exchangers. Solids Handling: Unique among mid-tier simulators, NXT has strong solids modules: crushers, screens, crystallizers, and fluidized bed dryers.
Flowsheet Features
Recycle Loops: Automatic tear stream identification and Wegstein / Broyden acceleration. Sensitivity Analysis: Automate the calculation of "what-if" scenarios (e.g., reflux ratio vs. product purity). Optimization: Built-in SQP (Sequential Quadratic Programming) optimizer for minimizing energy cost or maximizing profit.
Part 3: The "NXT" Differentiators – What's Actually New? If you used ChemCAD 7 or 8, what makes NXT worth the upgrade? 1. The Modern UI: Ribbon Interface & Flowsheet Canvas