Claude went back to answering a question about how black powder was made historically in full.

Black powder manufacturing in the 18th century was one of the era's most important — and most dangerous — industries, and it evolved considerably over the century. Here's an overview of how it worked historically.

The three ingredients

Saltpeter (potassium nitrate) was the hardest to obtain and made up the bulk of the mixture. Two main sources existed:

• •Imported niter, mostly from Bengal, where natural deposits and long-established local refining supplied the European market. The English East India Company's control of this trade was a significant strategic advantage, and saltpeter often served as ballast on returning ships.
• •Domestic niter beds, used where imports weren't available. These relied on the slow bacterial conversion of organic nitrogenous waste — stable sweepings, manure, urine collected from households — layered with earth and ash, kept damp and turned periodically over a year or more, then leached with water and the liquor boiled down and crystallized. France under the Régie des poudres (with Lavoisier as an administrator from 1775) systematized this, and the American colonies scrambled to establish such works during the Revolution, with limited success.

Sulfur came largely from Sicily and southern Italy, where volcanic deposits were mined and crudely refined, then purified further by distillation or sublimation at the powder works.

Charcoal was made locally by charring soft woods — willow, alder, and buckthorn were favored — in closed retorts or pits. Mill operators learned empirically that wood species and charring temperature mattered a great deal to the finished product's behavior.

Processing

The classic proportions — roughly three parts saltpeter to one part combined sulfur and charcoal — had been established since the late medieval period and were essentially standardized by the 1700s, though individual works guarded their variations for different grades.

Early in the century, many mills still used stamp mills: banks of heavy wooden pestles, driven by waterwheel cams, pounding the dampened mixture in mortars. These were notoriously prone to setting off the charge through friction. Over the century they were progressively replaced by edge-runner mills (also called incorporating mills), in which two large stone or iron wheels rotated on a circular bed, crushing and blending the moistened mixture for hours. This was gentler and produced more uniform "mill cake."

The mill cake was then pressed into dense slabs, and the slabs broken and corned (granulated) by forcing the material through sieves of graded mesh — coarse grains for cannon, fine for muskets and priming. Corning, which had become standard in the 16th–17th centuries, was crucial: uniform grain size gave predictable burning rates and much better performance than loose meal powder.

Finally the grains were glazed by tumbling in barrels, sometimes with a trace of graphite, which rounded and polished them, reduced dust, and helped resist moisture. The powder was then dried in gloriette drying houses or stove rooms and dusted before packing in barrels.

Organization and hazards

Works were laid out as scattered clusters of small buildings separated by earthen blast walls and trees, so an explosion in one would not propagate. Buildings often had deliberately weak roofs to vent blasts upward. Workers wore leather or felt shoes without nails, tools were made of bronze or wood, and iron was excluded from processing areas.

Even so, explosions were routine. Major works — Faversham and Waltham Abbey in England, Essonne in France, and from 1802 the Du Pont works on the Brandywine in Delaware — all suffered repeated fatal accidents, and the histories of these sites are punctuated by them.

Quality control

Powder was tested with an eprouvette — small devices that measured the force of a sample charge by how far it threw a weighted arm, lifted a weight, or propelled a ball from a small mortar. These were crude and inconsistent between designs, which was a persistent frustration for artillery officers, but they allowed rough grading and rejection of bad lots.

Broader significance

The 18th century saw powder-making shift from a craft practiced by small proprietors toward state-supervised or large-scale industrial production, driven by the enormous consumption of the era's wars. The French Régie's reforms under Lavoisier — improved niter refining, standardized proportions, systematic testing — substantially increased both output and quality, and are often cited as an early example of applied chemistry serving the state.

If you're interested in a particular thread — the saltpeter trade, the engineering of the mills, or a specific national industry — I'm happy to go deeper. Museums at Faversham, Waltham Abbey Royal Gunpowder Mills, and Hagley (the original Du Pont site) all have good published material on the surviving physical evidence.