Review of Open Source Process Simulators Empower Your Engineering Projects with CAPE‑OPEN Tools That Compete with Commercial Software
Simulation tools used to cost tens of thousands of dollars are now being outpaced by powerful open-source alternatives. These tools bring fully CAPE‑OPEN compliant environments, robust thermodynamics, and dynamic flowsheeting—all without licence fees. Perfect for small firms, startups, and academics.
1. DWSIM – Robust, Versatile, and Validated
DWSIM is the crown jewel of open-source process simulators. Designed for chemical and biochemical process modeling, it includes a full suite of unit operations, robust thermodynamic packages, and CAPE-OPEN compliance. Its dynamic simulation capabilities now span mobile platforms, making it ideal for education, prototyping, and full-scale design. Recent academic studies show it performs within 1% accuracy compared to Aspen HYSYS, validating its industrial relevance. The latest versions support bioethanol and fermentation process modeling, making it a leading tool for bio-based simulations.
Who it’s for: Professional engineers, consultants, and academics needing a validated, full-featured simulator without license fees.
It can be upgraded to professional version with the full support and advanced features for professional use.
2. COCO Simulator – Modular & Academic-Friendly
COCO (Cape-Open to Cape-Open) is built for flexibility and ease-of-use. It’s a steady-state simulator with flowsheeting capabilities and plug-in compatibility. COCO shines in educational environments due to its transparent structure and modular design. It integrates well with ChemSep, making it a great introduction for students learning distillation and separation. While not as extensive as DWSIM, it’s ideal for smaller modeling problems and proof-of-concept work.
Who it’s for: Educators, students, and researchers looking for a clean, intuitive learning platform.
3. EMSO – Customizable and Equation-Oriented
The EMSO (Environment for Modeling, Simulation, and Optimization) simulator is a power-user’s dream. Built for flexibility, it uses an equation-oriented approach to allow deep customization of unit models. You can code directly in EMSO’s modeling language and extend functions in C/C++ or Fortran. It's ideal for dynamic simulations and optimization tasks that go beyond drag-and-drop modeling. EMSO is part of the ALSOC project and is actively developed with a strong user base in Latin America and Europe.
Who it’s for: Engineers and modelers needing high customizability, especially for dynamic systems.
4. OpenModelica – Multi-Domain Modeling Power
OpenModelica is a general-purpose simulation platform built around the Modelica language. Though not exclusively for process simulation, it becomes extremely powerful when combined with CAPE-OPEN components and thermodynamic packages from ChemSep or DWSIM. It excels in hybrid simulations—combining mechanical, thermal, and chemical domains—and supports large-scale systems modeling. It’s widely used in academia for control systems and digital twin development.
Who it’s for: Researchers and developers working on hybrid systems, control, or integrated plant simulations.
4. BioSTEAM – Bioprocess Design Reimagined
BioSTEAM is a rising star for bio-refinery modeling and techno-economic analysis (TEA). Built in Python, it’s lightweight, scriptable, and built to integrate with economic evaluations. Its modular design makes it perfect for sustainability studies, process comparisons, and academic research in the bioeconomy. While still under active development, it’s gaining traction for its clarity, transparency, and flexibility.
Who it’s for: Bioprocess engineers, sustainability researchers, and anyone modeling next-gen, green tech.
Summary
| Simulator | License | Best For |
|---|---|---|
| DWSIM | GPL 3.0 | Full-scale process & bioprocess simulation |
| COCO | CAPE-OPEN non-commercial | Education, basic steady-state modeling |
| EMSO | ALSOC Open | Custom equation-based dynamic models |
| OpenModelica | OSMC-PL 1.2 | Multi-domain modeling & steady-state thermo |
| BioSTEAM | BSD-3 | Bio-refinery design & TEA workflows |
Final Word
In 2025, open-source tools no longer lag, they stand toe-to-toe with proprietary giants. DWSIM leads the way, COCO and EMSO round out solid options, and emerging frameworks like BioSTEAM and OpenModelica keep pushing boundaries. For engineers and researchers looking to advance without breaking budgets, this is the best moment to embrace free process simulation.
Resources
- DWSIM official downloads & documentation
- COCO Simulator homepage
- EMSO and OpenModelica community sites
