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Introduction
In this article I'll be writing about two basic skills:
1. How to make black powder using 4 basic methods, ranging from the use of
only two simple screens, through the use of a star-roller, hydraulic press,
and/or a ball-mill.
2. How to test various black powders to compare their power, and to determine
how much to use when lifting a typical fireworks aerial shell.
I hope this article will be useful for both the novice fireworker, and for the most
experienced one.
Black powder is perhaps the most basic and useful of all fireworks ingredients. It is
used to lift shells, comets, mines, Roman candle stars, and as a base-composition
in some rockets and many other fireworks components and devices.
Here is the definition of black powder taken straight out of the The Illustrated
Dictionary of Pyrotechnics (BK0043):
"Black powder - An intimate mixture of finely powdered potassium nitrate (75%),
charcoal (15%), and sulfur (10%). Commercial black powder may be granular or
finely powdered. It serves as a propellant and has a wide variety of uses. Black
powder should not be confused with smokeless powder, which is not a suitable
substitute for black powder (in fireworks)."
You can buy some types of black powder. There are two types available, sporting
and blasting. The sporting grades of BP, made by Goex and others, are readily
available from some gun and sporting goods shops, and some online sources. These
are the "Fg, FFg, FFFg, FFFFg, " etc. grades listed in the black powder grain
size charts.
The blasting grade, "A" powders are most frequently used in fireworks. 2FA, 4FA,
and Meal-D are the sizes we need the most. They are available only to holders of a
BATFE explosives license.
If you can find BP at your local gun shop, it usually retails for $16 - $24 per pound.
Beginner shell makers can easily use more than 50 pounds of 2FA per year. That's
about $1,200 at retail! It doesn't take long, buying commercial BP, before you start
asking yourself, "Self, ain't there a less expensive way?"
Even if one has the BATFE license to buy commercial 2FA in bulk (50 or 100 lbs at a
time), the current price of it is $7-8 per pound.
So, economics, practicality, availability, and the pride of actual fireworks-making, all
eventually make it inevitable that most pyro-hobbyists will make their own BP. And
the good news is that it is Federally legal to make it yourself, without an ATF
license. But, check your state and local laws first to make sure you can comply with
them as well.
Many would argue that the very first, important step to learning the art of
fireworking is tackling the skill of making high-quality black powder.
#1: The quality of the chemicals and the type of charcoal (wood species) that is
used. Willow charcoal is often being referred to as the wood of choice for BP
charcoal. I use spruce/pine as the wood that I turn into homemade charcoal. (This
subject is discussed in the Making Charcoal article.) I'll be comparing BP made with
this pine charcoal, with that made with commercial airfloat charcoal.
#2: The method used to pulverize and intimately mix the
ingredients. Screening through a fine-mesh screen or ball-milling can be
employed. (This subject is thoroughly explored in Ball Milling 101.)
#3: How the mixed ingredients are consolidated and granulated.
#4: The size of the granules, especially with BP that is made into pucks that are
broken up (corned).
First Step
I ball mill four 20-ounce batches of mill-dust BP, two batches using pine charcoal,
two more using commercial airfloat. Each batch has 15 ounces of potassium nitrate,
3 ounces of charcoal, and 2 ounces of sulfur. I run the ball mill for 2 hours for each
batch. I end up with 40 ounces of pine charcoal mill-dust, and 40 ounces of
commercial charcoal mill-dust.
(Mill-dust is the term that is used for BP as it comes straight out of the ball mill,
before any granulation.)
Second Step
I take 16 ounces of the pine charcoal mill-dust, add 1.6 ounces of water (10%) to
it, and thoroughly incorporate the water into the powder with my gloved hands.
Then I further incorporate the water with a screen colander. I press 1/8" thick pucks
with that powder. I have found that if I apply about 1600 psi of pressure on the
pucks when I press them, that they are as solidly consolidated as they are going to
get. I put the finished pucks into the drying chamber to dry.
I do the same with 16 ounces of the commercial charcoal mill-dust.
(I have found that it is quite easy to break the pucks up a bit by hand while they
are still damp. This makes it easier to granulate them later on.)
Third Step
I take 16 ounces of the dry pine charcoal mill-dust, add 0.8 ounce of dextrin (+5%)
to it, screen it to thoroughly incorporate it, and coat that BP onto 2.4 ounces of rice
hulls in the star roller (7/1 ratio of BP to rice hulls). I put the coated hulls on
screens and into the dryer. Although puffed rice cereal can be used in this process,
rice hulls make more durable grains.
Fourth Step
I take 8 ounces of the dry pine charcoal mill-dust, and dampen it with 1/3 cup of
denatured alcohol (from Home Depot) in which I previously dissolved 1/10 ounce of
red gum (about 1% of the mill-dust weight). I slowly add enough additional alcohol
to the mill dust, only as much as necessary, to end up with a nice, putty-like
"dough ball." Then I granulate that dough-ball through a 1/4" (4 mesh) screen onto
a kraft-paper lined tray for drying.
Fifth Step
I simply take 15 oz. of potassium nitrate and screen it through a 100 mesh screen.
If all of it won't pass the screen, I mill it a bit in a small coffee grinder until it will
pass the screen.
Warning: I never mill anything but individual chemicals in the coffee grinder. I use
one coffee grinder only for oxidizers, and a different one for fuels. I thoroughly
clean it after using it for one chemical.
Then I combine that 15 oz. of potassium nitrate with 3 oz. of pine airfloat charcoal
and 2 oz. of sulfur, and pass them twice through the 100 mesh screen to thoroughly
mix them.
This 20 oz. batch of BP chemicals is then wet with about 3/4 cup of the denatured
alcohol which has 0.2 oz. of red-gum dissolved in it. More alcohol is added as
needed and the putty is granulated as in Step 4 above.
I do the same for a similar batch using the commercial airfloat charcoal.
Many of you are now saying, "Aw, he's never gonna get a useful BP with that simple
screening method. It has to be ball-milled." You just wait.
All of the powders produced above are left in the drying chamber until they are
completely dry.
Some Observations
Coating the rice hulls and processing the resulting grains is relatively easy, and the
alcohol/red gum granulated powder is probably the easiest to produce. It is a bit
more expensive to make, though, since the red gum and alcohol cost a little more
than dextrin and plain water.
Results
So, now I have my 10 homemade powders to compare with each other. I also have
some German Wano 2FA powder (equivalent to Goex 2FA) which I screen and
separate into 4-8 mesh and 8-12 mesh powders, as I did with the homemade
powder made from pucks.
Pine charcoal, simply screened BP, processed with alcohol and red-gum
Commercial charcoal, simply screened BP, processed with alcohol and redgum
Wano 2FA
Wano 3FA
Now I'd like to test these 12 BP's and compare their relative performances.
To what extent does the type of charcoal affect the power of the BP?
How much should I use of one of these BP's to lift an aerial shell?
I have to admit that the process I'm about to describe is where my creative juices
really start flowing in this hobby. Being curious about something, thinking about it,
doing some experimenting, pondering the results, and coming to some conclusions
that are useful in my future activities--that's what this is all about for me.
We have quite a few variables in the above information when it comes to choosing
how to make powerful BP and how to use it in our pyro projects.
I want to design an experiment to compare black powders which incorporate these
different variables, in order to know how each of those variables affects the BP's
power, and to be able to determine which materials and techniques are preferable
when making my BP.
I have my 12 different types of black powder sitting in front of me. Now I'll test
them in various amounts, lifting dummy shells, to compare their relative
performances, and to find out exactly how much of each of them to use when lifting
an actual fireworks shell.
For testing my 12 BP's, I'm going to use my version: "Pyro-Baseball." With "PyroBaseball," I use baseballs and a 3" mortar to simulate the lifting of 3" spherical
fireworks shells. Baseballs are just the right size and weight. They save me the
time, expense, and hassle of having to build actual dummy shells.
For my tests, I'm using a one-piece, HDPE (high-density polyethylene) "gun."
Whichever gun you use, it is a good idea to use the same mortar for all of the
comparison shots. This will minimize variations from one test to another.
On page 140 of The Best of AFN II (BAFN II) are some charts showing
recommended BP lift amounts for various types and sizes of shells. Table 1 indicates
that, for lifting a 3" ball shell, 0.6 oz. of FFg, or 0.75 oz. of 2FA would be
appropriate amounts of commercial lift powder.
And, on Page 17 of the PGI's Display Fireworks Operator Certification Study Guide,
one can find a nifty table that shows the typical (desired) heights that various size
fireworks shells ascend to before bursting. This table shows that a 3" fireworks shell
would rise to about 300 feet and then burst.
That's good information to have. Using about 0.6 to 0.75 ounces of my Wano BP
ought to send one of my baseballs up to about 300 feet. I can weigh that amount,
drop it down into the bottom of a 3" mortar, insert 4" of visco into the fuse hole at
the bottom, drop a baseball into the gun, and light 'er up.
average total flight-time, the time from apogee to ground is about 2/3 of the total
flight time from lift to landing.
With this powder, I'd use 0.5 oz. to reliably lift a 3" ball to 300'.
We did this with each powder, firing baseballs about 40 times into the air.
Results
Repeating the tests described above with each of the 12 BP's, I was able to
determine the optimum amount of each powder for lifting a baseball to 300'.
0.30
0.35
0.40
0.45
0.50
0.55
0.60
0.75
0.75
0.75
0.75
0.75
0.90
oz.
oz.
oz.
oz.
oz.
oz.
oz.
oz.
oz.
oz.
oz.
oz.
oz.
Note: It was almost difficult to use a small enough amount of the pinecharcoal/red-gum-alcohol powder. A third of an ounce is a mighty small amount of
lift powder.
Answers
To what extent does the type of charcoal affect the quality of the resulting
black powder?Homemade pine charcoal produced powder that was marginally
better than that produced with the commercial charcoal, but both can produce BPs
that far outperform commercial black powders.
How did the 4 methods of processing/granulating the BP's compare when
the resulting powders were tested? All three methods that employed ballmilling produced powders that were very comparable. The method that used
simply-screened chemicals produced BP that, while not as powerful, was very
functional in amounts comparable to commercial 2FA.
How does the size of the granulation of pressed pucks affect
performance? For these 3" dummy shells, the finer 3FA (8-12 mesh) granulation
Final Conclusion
For my purposes, either homemade or commercial charcoal produces completely
satisfactory powder. I really like the ease of production, and the final resulting
powder when the red-gum/alcohol method is employed to make BP, so I'll probably
use that method when making lift powder for aerial fireworks shells.
To me, the simply-screened, red-gum/alcohol method looks like the method-ofchoice for simple, field-expedient, very functional black powder, and it can be
produced without any complex or expensive machinery. This method is ideal for the
beginning fireworker.
I think I'll bring my bucket of baseballs and a couple of 3" mortars to the
next PGI convention, and whoever is interested can take to the field with me to go
head-to-head with our prize black powders. May the best pyro win!
Enjoy and Stay Green,
Steps
1.
1
Purchase the items you can. This is one of those instances where
the better quality the ingredients you have, the better quality product
you will produce. The saltpeter and the sulfur can be found in most
drug stores.
Ad
2.
Make your charcoal. Willow, birch, fir, oak, beech and ash, when
charred properly, are good woods to choose when selecting wood for
your charcoal. Place the wood chips in a large pot with a lid or a 55
gallon (208 liter)barrel with a lid, just make sure there is a little open
area (a crack where the lid meets the container or a small hole) so
some steam can escape. Build a fire under your container. When
steam begins to exit the container, light the wood inside and reclose
the lid. Let the fires burn out and wait for everything to cool. What is
left inside your container is your charcoal.
3.
3
Grind your ingredients separately. Use a mortar and pestle or hand
mill to grind the potassium nitrate. Set it aside. Grind the charcoal. Set
it aside. Grind the sulfur into a powder as well, and then set it aside. It
is very important to grind everything individually. You may also choose
to use a ball mill. If this is the case, place your crushed charcoal and
your sulfur in the mill, and run the mill for several hours. Once ground
to a fine powder, remove from the mill.
4.
4
Chill 2 1/2 cups (or 600 ml) of isopropyl alcohol for every 100
grams of charcoal/sulfur mix you have. Once cold, mix with the
charcoal/sulfur mixture.
5.
5
Measure your ingredients. The components of black powder used to
be measured by weight. This has been calculated out, nowadays, as
75 parts potassium nitrate, 15 parts charcoal and 10 parts sulfur (or
25% charcoal/sulfur mix).
6.
6
Prepare your nitrate. Measure 1/4 cup (or 40 ml) of water for every
100 grams (about a 1/2 cup) of potassium nitrate in an old pan. Add
your potassium nitrate. Bring to a boil. Stir continuously. Add little bits
of water at intervals until the potassium nitrate is completely dissolved.
7.
7
Add the charcoal/sulfur mix to your pot of boiling potassium
nitrate. Stir until all ingredients are completely combined.
8.
8
Take your chilled alcohol and your hot mixture outside. Add the
hot mixture to your isopropyl alcohol. Stir together.
9.
9
Chill this new mixture. The more quickly you can chill this to 0
degrees Celsius, the better.
10.
10
Filter the mixture through cheesecloth or an old cloth. This will
remove all the liquid from the solution. Throw out the liquid that got
filtered out.
11.
11
Lay the mix out on a piece of paper to dry in the sun.
12.
12
Press the mixture through a sieve while it is still slightly
damp. Spread it out on your paper again and allow it to dry some
more.
13.
13
Run the powder through the sieve or a series of mesh screens a
few more times to get it completely broken up.
14.
14
Store your black powder in a cool, dry place in cans. Make sure to
choose a place that is out of the reach of children.
1.
1
Get your hands on some saltpeter. Saltpeter is the common name
for potassium nitrate. In the days when black powder was widely used,
saltpeter was manufactured from bat guano or made from horse urine
and other "manurial soils."[1] It's used in many fertilizers, as part of
science projects, and in certain recipes. You have several options for
sourcing saltpeter:
Look for "stump remover" in garden stores. Saltpeter is
often sold under this name. You may also find it labeled as saltpeter,
niter, or potassium nitrate.[2]
Buy it online. If you do a search for saltpeter, you'll get
plenty of results, and you can easily have a bottle delivered to you.
Make it yourself out of a cold pack. Cold packs you can buy
for a few dollars to help with sore muscles contain sodium nitrate and
water, and can be used to make saltpeter.
Make it with urine. This is definitely the most difficult way to
2 2
Obtain charcoal. You can use standard charcoal that you buy to cook
with your grill, which you'll need to grind to a fine powder. If you're a
purist, make your own charcoalby filling a metal drum with 3-inch
pieces of willow or another wood, then placing the drum in a bonfire
with a loose lid on top (to allow for airflow). Keep the bonfire piping hot
for 4-6 hours, then open the drum. The wood will have charred into
fine pieces of homemade charcoal, perfect for use in gunpowder.
3 3
Get elemental sulfur. This naturally-occurring substance is often
used to acidify soil, so you can find it in garden stores or from online
sources that sell garden supplies. Elemental sulfur occurs naturally
and is mined from beds in Texas, Louisiana, Italy, and other locations
around the world.[4]
1. 1
Finely grind the ingredients. Use a mortar and pestle to grind each
ingredient into a fine powder. Grind each ingredient separately,
cleaning the mortar and pestle in between uses.
2
Measure out the gunpowder components. Using the right ration of
ingredients is very important when you're making gunpowder.
Calculate the percentages by weight, using a small scale to weigh the
different ingredients. Here's how much you need:
3
Mix the ingredients together. Place them all in the mortar and grind
them together with the pestle for 10 minutes or longer. If you're using a
ball mill, mill the charcoal and sufur together for 4 hours first, then add
the saltpeter and mill the mixture for another 24 hours.
4 4
Consider adding water. Some say adding up to 8% water can
improve the gunpowder's burning. Continue mixing the gunpowder,
adding water in small increments until the gunpowder is the texture of
thick clay. Form it into a ball when you're finished.
If you mix the gunpowder with water, you'll need to corn the
gunpowder, or break it up into small pieces. Run the gunpowder ball
through a kitchen sieve to break it into small pieces, then let the pieces
dry out on a piece of paper.[5]
5 5
Store the black powder safely. Place the black powder in a special
container designed for gunpowder. Consider storing it in a fireproof
box in a shed or another area outside your home. In any case, store
the black powder in a stable area where it will not come into contact
with a flame or be exposed to high temperatures.
You can buy powder containers at hardware stores or
online.
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