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 ToolBlast-to-Mill Feedback Loop
Compare blast design predictions against measured fragmentation. AI-powered analysis with design recommendations and trend tracking.
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 ToolStarkey SPI + Bond SAG Specific Energy
Predict SAG and ball mill specific energy using the Starkey SPI laboratory test and Bond Ball Mill Work Index with diameter and fines corrections. Includes scatter chart of 32 published mine site benchmarks.
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 2,500+ 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 ToolHPGR Phenomenological Model
Predict HPGR throughput, power draw, and product size distribution using the Austin, Weller & Lim (1993) phenomenological model. Includes 4 power estimation methods, roll crusher breakage model, and sensitivity analysis.
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 ToolCircuit Design Assistant
AI-guided comminution circuit design from ore properties to final equipment selection. Chains multiple calculators together with expert reasoning.
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 ToolArterburn Hydrocyclone Sizing Calculator
Size hydrocyclones using the Arterburn (1982) method with correction factors, capacity curves, and 16-cyclone database. Verified against the original Krebs Engineers paper.
Launch ToolNageswararao Hydrocyclone Model
Full Nageswararao (1978/2004) hydrocyclone classification model with user-editable K constants, JKSimMet lambda toggle, fish-hook efficiency curve, 13 source-traced geometry presets, and three-tier validation.
Launch ToolSAG Mill Discharge & Transport Calculator
Analyse SAG/AG mill discharge behaviour using Morrell slurry hold-up, Mitchell aperture classification, pebble port models, SDV calculator & benchmarking (Powell & Valery 2006, 7 panels, 9-mill database), and grate design comparison.
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 ToolMorrell C-Model Power Draw
Full mechanistic energy-balance power prediction from Morrell's 1993 PhD thesis. Calculates PE + KE of the charge, cone-end power, overflow/grate discharge effects, and no-load losses with K = 1.215.
Launch ToolMorrell E-Model Power Draw
Semi-empirical algebraic power prediction from Morrell's 1993 PhD thesis. Uses fitted filling (γ) and speed (δ) functions with K = 7.66 (overflow) or 8.81 (grate). Fewer inputs than the C-Model.
Launch ToolValle Power Draw
Predicts gross power at the motor (kW) for SAG, AG, and ball mills using Valle's 2024 IMPC model. Shows all intermediate values including charge density, equivalent length, and aspect ratio.
Launch ToolAustin SAG Mill Power Draw
Austin (1990) SAG/AG cylinder power model calibrated by Doll (Procemin 2013, IMPC 2016) against 49 published mill surveys. Predicts shell power with cone correction and DCS efficiency conversion.
Launch ToolVizcarra SAG Specific Energy
SAG mill specific energy prediction using the Vizcarra (2023) model structure with Daniel’s (2026) recalibrated constants fitted to 37 Newmont/Siddall data points. Accounts for ore hardness (Mia), feed size, ball load, speed, aspect ratio, and screen aperture.
Launch ToolMorrell Slurry Hold-Up Estimator
Morrell-Stephenson two-zone grate flow model for AG/SAG mills. Predicts slurry accumulation, pooling onset, flow regime curves, charge density, and sensitivity analysis. Validated against 6 Leinster industrial datasets.
Launch ToolGrinding Media Wear Calculator
Predict SAG & ball mill grinding media wear rates from ore properties using Giblett & Seidel (2011) empirical correlations. Estimate annual media consumption and costs across 5 models.
Launch ToolOre Intelligence Hub
Build a complete ore profile from any combination of test data. Auto-derives missing parameters via 26 correlation equations, finds similar ores in 2,794-sample database, and shows which tools are ready to use.
Launch ToolCement Mill Design Suite
Clinker chemistry (Bogue formulas), ball mill sizing (Bond energy with fine grinding correction, critical speed, ball size, charge volume), vertical roller mill forces and table speed. 4 tabs, 16 equations, 4 manufacturer datasets. Based on Oliveira (UFRJ, 2012).
Launch ToolComing Soon
Binary SAG
COMING SOON
Multi-Comp SAG
COMING SOON
Built by the Engineer Who Developed the Models
Dr Mike Daniel
PhD, MSc, B.Sc. (JKMRC, University of Queensland). Principal Consultant, CITIC-SMCC.
35+ years of independent grinding circuit consulting across open-pit and underground operations on six continents.
- Morrell power models (1993, 1996, 2004)
- Bond energy framework (1961)
- Austin SAG mill model (1990)
- Daniel & Morrell HPGR models (2002)
- Stange binary SAG model (1996)
- Arterburn hydrocyclone model (1976)
Every model traceable to peer-reviewed publications.
Mining Databases
Industry Reference Data
Equipment Database
Comprehensive database of tumbling mills and stirred mills with vendor specifications, operating data, and global installation records.
2,500+
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
Mill Location Database
Validated mine-to-mill installations across 41 countries with mine ownership, coordinates, commissioning data, and reference sources.
370+
Records
41 countries, 33 mines
Coverage
Global Mines Database
1,288 mines across 21 commodity types worldwide with GPS coordinates, ownership data, and mine type classifications. Free and open access.
1,288
Records
21 commodities, 88 countries
Coverage
Comminution Testing Labs
Directory of 50+ comminution testing laboratories across 6 continents. Compare capabilities across 36 test types including Bond, DWT, SMC, HPGR, and ceramic media testing.
50+
Records
6 continents, 36 test types
Coverage
“Get the comminution circuit right, and you optimise everything downstream — energy, throughput, and operating cost.”
Dr Mike Daniel — Principal & Managing Director
35+ Years of Mining Excellence
Daniel & Sons was founded with a simple mission: bring rigorous engineering analysis to comminution circuit 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 & Managing Director
Dr Daniel is an independent grinding circuit consultant with over 35 years of experience in comminution circuit design, HPGR technology, process audits, and Eco-Comminution®. His work spans open-pit and underground operations across six continents, with clients including Barrick, Anglo American, BHP, Rio Tinto, and Newmont.
- PhD, MSc, B.Sc. — JKMRC, University of Queensland
- Principal Consultant, CITIC-SMCC Pty Ltd
- Licensed Morrell Power Modelling Methodology (DMCC Pty Ltd)
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