Precision Engineering for Modern Mining
Advanced blast fragmentation modelling, mill optimisation tools, and AI-powered site analysis. Built for engineers who demand accuracy.
Free Engineering Tools
Professional-Grade Tools & Databases
Blast Fragmentation Calculator
Demenegas model implementation with PSD curve fitting, rock factor analysis, and real-time comparison against measured data.
Launch ToolAI Image Analysis
Upload blast site photos for instant AI-powered segmentation. Identify rock fragments, equipment, and blast patterns automatically.
Launch ToolTower Mill Power Calculator
Calculate power draw and sizing for vertical tower mills (VTMs). Four power models, installed database, and auto mill recommendation.
Launch ToolBarratt Tent Diagram
Interactive SAG mill operating envelope. Morrell (1993) and Austin (1990) power models with motor capability curves.
Launch ToolComminution Correlation Calculator
Input any single comminution test parameter and auto-derive 7 related ore properties using 33 regression equations from 2,799 samples.
Launch ToolBond Work Index Calculator
Estimate comminution circuit specific energy using Bond's Third Law with Rowland correction factors (EF1–EF7). Multi-stage crushing, rod milling, and ball milling.
Launch ToolSAG Mill Specific Energy Calculator
Predict SAG mill circuit specific energy using three methods: Morrell SMC/CEET, SAGDesign SGi, and Bond equivalent. Integrates with ore property database for testwork-based estimation.
Launch ToolTumbling Mill Power Draw Calculator
Predict power draw for SAG, AG, ball, and rod mills using Morrell (1993), Austin (1990), and Bond models. Validated against 3,500+ installed mills from the equipment database.
Launch ToolSAG Mill Sizing Tool
Select the right SAG mill size (diameter x length) for a given ore and throughput target. Iterates standard mill dimensions using Morrell and Austin power models, ranked against 800+ installed SAG/AG mills.
Launch ToolBall Mill Sizing Tool
Select the right ball mill size (diameter x length) for a given ore and throughput target. Uses Bond energy with Rowland corrections and Morrell power model, validated against 1,568 installed ball mills.
Launch ToolPrimary Crusher Sizing Tool
Gyratory and jaw crusher selection with throughput and power verification. Bond crushing energy model with catalog of 14 standard primary crusher sizes.
Launch ToolCone Crusher Sizing Tool
Standard and shorthead cone crusher selection for secondary and tertiary crushing. Bond crushing energy model with catalog of 13 HP/MP series crusher sizes.
Launch ToolHPGR Unit Model
Predict HPGR throughput, power draw, and specific energy using Morrell/Daniel models. Catalog of 9 standard HPGR sizes for equipment selection.
Launch ToolHPGR Circuit Model
Model open and closed circuit HPGR configurations with screen or air separator classification. Iterative circuit convergence with pass-by-pass energy breakdown.
Launch ToolStirred Mill Sizing Tool
Size stirred mills (Vertimill, IsaMill, HIGmill, TowerMill) for regrind applications using Bond and Morrell Mih energy models. Validated against 193 installed stirred mills from 4 vendors.
Launch ToolMine-to-Mill Data Checklist
Comprehensive data collection checklist for mine-to-mill optimisation studies. 117 items across 4 sections with progress tracking.
Launch ToolTotal Circuit Specific Energy Calculator
Calculate total comminution circuit specific energy across all stages. Compare 7 circuit configurations (SABC, SAB, 2CB, 3CB, HPGR+BM, SS-HPGR, ABC) using Bond, Morrell, and empirical models.
Launch ToolNumber of Samples Calculator
Calculate the number of samples needed for target accuracy using CV, confidence level, and ore type presets. Based on Gy's sampling theory with 13 commodity CV defaults.
Launch ToolMill Volume & Charge Calculator
Calculate mill internal volume, charge composition (ball, rock, slurry, void), fill level geometry, and mass balance for SAG, AG, and ball mills.
Launch ToolLiner Effective Height Calculator
Calculate mill liner effective height, wear rate, remaining life, and replacement scheduling. Track liner profile evolution over time.
Launch ToolHydrocyclone Sizing Calculator
Size hydrocyclones using Plitt (1976), Nageswararao (2004), and Arterburn (1976) models. Compare d50c, cyclone count, and efficiency curves across models.
Launch ToolSAG Mill Discharge & Transport Calculator
Analyse SAG/AG mill discharge behaviour using Morrell slurry hold-up, Mitchell aperture classification, pebble port models, and SDV comparison across 9 reference mills.
Launch ToolBinary Ore SAG Simulator
Population balance SAG/AG mill simulator with binary ore tracking. JK breakage model, grate classification, and iterative steady-state convergence. Based on Stange (1996) with Bueno (2010) validation.
Launch ToolOre Breakage Characterisation
Dual surface/body breakage model for AG/SAG mill ore characterisation. Separates low-energy surface damage from high-energy body fracture with energy threshold zones. Based on Larbi-Bram (2009) PhD, JKMRC.
Launch ToolJankovic Stirred Mill Power Model
Mechanistic power model for vertical stirred mills (tower/screw and pin types) based on Jankovic (1999). 7 power components with media velocity model and Janssen pressure distribution.
Launch ToolCarvalho Mechanistic SAG Model
Mechanistic SAG mill model based on Carvalho (2013): DWT breakage, Tavares fracture energy, damage accumulation, appearance function, and mill power draw (Morrell + Austin).
Launch ToolMulti-Component SAG Simulator
N-component population balance SAG/AG mill simulator. Extends Stange (1996) binary model to any number of ore types with independent JK breakage parameters. Based on Bueno et al. (2010).
Launch ToolMining Databases
Industry Reference Data
Equipment Database
Comprehensive database of tumbling mills and stirred mills with vendor specifications, operating data, and global installation records.
3,500+
Records
9 vendors, global installations
Coverage
Ore Property Database
Alex Doll Public Testwork Database (corrected) with Bond work indices, comminution parameters, and mineralogical data from worldwide ore samples.
2,800+
Records
Major ore types worldwide
Coverage
“Every blast is a precision engineering exercise. Get it right, and you optimise everything downstream.”
Dr Mike Daniel — Principal Consultant
Three Decades of Mining Excellence
Daniel & Sons was founded with a simple mission: bring rigorous engineering analysis to blast design and mineral processing.
Over three decades, we've worked with mining operations on every continent, from small gold mines to the world's largest copper producers. Our approach combines academic rigour with practical field experience.
Today, we continue that mission with modern tools—including AI-powered image analysis and advanced fragmentation modelling—while never losing sight of the fundamentals.
What We Do
Areas of Expertise
Blast Design
Pattern design, powder factor optimisation, fragmentation prediction, and vibration control for open-pit and underground operations.
Mine-to-Mill
End-to-end optimisation from blast to crusher to mill. Reducing energy costs and improving throughput through integrated analysis.
Technical Training
On-site and remote training programs for drill & blast crews, engineers, and management teams at all experience levels.
Track Record
Proven Results
Leadership
Principal Consultant
Dr Mike Daniel
Principal Consultant & Founder
Dr Daniel brings over 30 years of hands-on experience in blast engineering and mineral processing to every project. His work spans open-pit and underground operations across six continents.
- PhD Mineral Processing, University of Queensland
- MEng Rock Fragmentation, Luleå University of Technology
- FAusIMM, Chartered Professional (Mining)
- Member, International Society of Explosives Engineers
Ready to Optimise?
Get in touch for a free consultation. We'll discuss your operation and how we can help.
mike.daniel@cmdconsulting.com.au