just because our government attaches a label to black powder as an explosive and another label on pyrodex and other substitutes as propellants does not make either type of powders one thing or another.
in my opinion, there is a lot of hype and fear related to black powder, much of it wholly unfounded.
the only way it is going to explode is if you confine it, same as with pyrodex and others
it will not ignite with common levels of static electricity (wilmhurst machines and the like excluded), it is not going to ignite if you hit it with a hammer, it needs a relatively hot spark, and depending on the level of sulfur that temperature can be quite high.
this is not to say that it is possible to make black powder that might be more shock sensitive or pressure sensitive or whatever sensitive...
99% of the explosions relating to black powder production back in the day relate to good housekeeping or rather poor housekeeping standards and lack of good precautionary standards.
its no secret that i make my own black powders, and i suspect they are every bit as good as those powders commonly available back in the mid 1800's , save for maybe some stuff made by military arsenals. this is what i have found.
static will not set it off
hitting a pinch of it on an anvil with a hammer will not set it off, it will however make nice thing flakes of powder.
it takes heat! and to make it go boom it must be contained, the better it is contained the better the boom.
my powder will flash just as fast as any other powders i have compared it too, and some of it will flash faster, so it is not a slow burning powder that is the root cause that keeps it from being pressure, static sensitive.
the best powders i have made, if you put a small pile of perhaps 50gr of ffg or even fffg on a piece of newspaper, and then set the edge of the paper afire, will when ignited (and it won't ignite every time, more on that later) flash off and leave the paper with readable print after the poof!
no it doesn't flash everytime, sometimes the paper will burn down to a very small flame as it approaches the powder and simply go out right at the edge of the powder... the flame must get enough heat to the first grains of powder or its a no show.
the stuff is just not that sensitive in my opinion.
does this mean it isn't dangerous? hell no, and hell yes it is dangerous. you just work in small batches, work smart and keep your work area clean or all residue, and keep airborne dust to "none".
its the airborne dust that likely causes the vast majority of fires in powder plants across time. just as wheat dust will blow up a coop elevator, or coffee creamer, or any other product that can burn becomes explosive if it becomes airborne with the right ratio.
i realize i am beating a long winded drum, but i really think black powder has gotten a bad rap, for reasons i have stated, when talking about commercial production... as for diy'ers that is another variable that for very good reasons the owners of this forum don't want detailed discussions about procedures and recipe's.
we all know someone that could destroy a crowbar in the deep end of a swimming pool. it is this sort of person that also tries to fire a stuck projectile or a broken ramrod out of a barrel with disastrous results. it doesn't take a very good imagination to see all the horror that might befall these sorts of individuals if they were to start making their own powder.
so in conclusion, black powder is not particularly dangerous, done right with reasonable caution and good sense, to manufacture. and it is not particularly dangerous to use if used properly. black powder can be made to have a rather wide range of power and velocity when used in a rifle, and it is likely that all this was exceptionally well understood by those that made rifles back in the day.
stepping off now, before someone starts throwing tomato's and and rotten fruits at me!
bob g