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The primary consideration for mechanical mixtures is homogeneity. Every sample of the mixture has to have exactly the same proportion of the ingredients, in the same configuration and relation to the other ingredients, as every other sample, no matter how large or small the sample is. The gunpowder manufacturer achieves this by pulverizing the ingredients to sizes that offer the best chance for a homogeneous mixture, mixing them for the time necessary to achieve gross homogeneity, and then “incorporating” the mixture in a circular trough by means of a pair of heavy rollers that slowly go around and around. Some dampening of the mixture with alcohol with a trace of water is done to assist in the incorporation of the soluble potassium nitrate into the charcoal, but the sulfur is insoluble, so must be physically pressed into the pores. Eventually, every particle of sulfur is the same distance away from every other particle of sulfur, surrounded by the same amount of potassium nitrate, and pressed evenly and completely into the pores of the charcoal. This crushing and filling of pores raises the density and energy of the mixture. Obviously, every manufacturer has their own ideas on how to accomplish this process, based on their own experience, testing, and customer response. These processes take time, and must be run and monitored by experts, which increases the cost. If you can sell the product at $25/lb because it’s easy to load for accuracy, you can take the necessary time. If your customers don’t mind a little finagling to get the powder to shoot well, you can take less time and sell it cheaper. If all they want is a bang, cheaper still. I very much doubt there are any “secret ingredients” in any of the black powder sold as such. The manufacturers have centuries’ worth of data on the safety and shelf life of the mixtures they make. Putting something new in there sets the data clock back to zero, in the most litigious era in human history. Dan Pawlak got himself killed developing Pyrodex, black powder modified with potassium perchlorate and sodium benzoate, which raised the ignition temperature and retarded fouling buildup. The regulators are always asking the explosives manufacturers to add “inert” taggants to their mixtures so they can see where the bomb came from. But “inert” is a century of no problems, despite varying conditions of manufacture, storage and use. Easy to demand someone else stick their neck out; uneasy for the stickee.
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