I've been experimenting with sulfur, potassium nitrate, and charcoal. I bought some charcoal and used a cheese grater to get it into powder form, then further ground it using a mortar and pestle, and finally filtered it through various sieves, the last one being extremely fine. I also ground the sulfur and potassium nitrate into powder.

Finally, I mixed everything together and ground it again using the mortar and pestle. However, when I tried to ignite the black powder, it burned but left behind some white residue. From what I’ve read, this might be because not all the potassium nitrate is participating in the reaction. I also tried igniting it on a piece of paper, but I still get some white spheres left over, reaction is very slow...

Considering I used the standard 75/15/10 ratio and 99% pure sulfur, the only reason I can think of is that the black powder isn't fine enough. I want to emphasize that the powder I made is practically like flour.

Since I didn’t use a ball mill, based on your experience, how many hours do you think I should spend using the mortar and pestle to get it fine enough?

Do you think the Corned process will make the gunpowder components react more quickly and leave no residue? Or is it just worsening the reaction time?

Hello, i did some research on making flash powder in the safest possible way. Normally i would use the Diaper Mix method but i will need to work on a pretty large production scale so Diaper mixing would take alot of time and i dont want any explosive flash powder stored near me when its not inside of the firecracker. I used the 2 pictures in this post for my information. People say binary mixing only works for large amounts but i tried it with only 6 grams and it worked flawlessly. I did the binary mixing with a remote controlled device so im not near the flash powder while its being mixed.

If ur interested or have any questions i can send the video of the result and the mixing process.