The powder intended for glazing is first exposed an hour to the sun on one cloth, in winter, and between two cloths in summer, in order to dry it more perfectly, which is very necessary before the operation of glazing. For this purpose, it is put into a vessel like a barrel, which is turned horizontally upon its axis, by machinery. This barrel is furnished with bars that go across, intended to augment the friction, or rubbing of the grain, and expedite the process. The barrels are made to turn slowly, to avoid breaking the grain, and at the expiration of eight or twelve hours, the glazing is finished, the powder having acquired a sufficient hardness and polish. After removing the powder, the dust is separated in the usual manner.
Gunpowder-mills are mills, in which powder is prepared, by pounding and beating together the ingredients of which it is composed. They are always worked by water-power, and as there are generally many of them belonging to the same manufactory, one dam of water will furnish a sufficient supply. In the construction of powder-mills, the frame of the house is made very stout, and the roof put on lightly, so that in case of explosion, it may be carried off easily, and thus give vent to the powder, without much injury to the works. The lights, to enable the work to be carried on at night, are placed on the outside of the building, beyond the reach of the powder, and by means of glass windows, the light passes into the mill. It is lamentable, indeed, that so many accidents occur in the operation of making powder. This may take place, as it has to our knowledge, by the friction of the pounders. Their weight, the rapid succession of the blows, and the dryness of the powder, are the principal causes of such accidents, and sometimes by the inattention of the workmen, suffering nails, and the like, to get among the materials. I once witnessed the effect of an explosion of the kind, in the neighbourhood of Frankford, in the vicinity of Philadelphia, at the old and well-known powder mills, at that place. It was produced, in consequence of the friction, by the neglect of the men not adding water at a proper time, to keep the materials moist. The mill in which the explosion took place was not much injured; but the roof, together with the men, were sent a considerable distance. Some of the latter fell into the mill-race, and were much injured. The effect, however, did not stop here; for the fire communicated, strange as it may appear, to some of the other mills, although at some distance, and blew them up. Several explosions have happened at the same mills.
An experiment, made at the same works, by the then proprietor, the father of the late commodore Decatur, by putting the nitre, charcoal, and sulphur, into a barrel, with iron balls covered with lead, which was turned upon its axis, terminated in the same way. It exploded, but no other injury or accident was sustained. On examining the balls, we found, that the lead was entirely worn off, and the explosion must have been owing to the iron. This experiment was performed, in order to find if the mixture could be made in this manner, a plan which was afterwards adopted in France, with success, but brass balls were used. In a series of essays, which I wrote for, and published in, the Aurora, in 1808, on the "Application of Chemistry to the Arts and Manufactures," as manufactures are vitally important to the practical independence of this country, I mentioned the subject of gunpowder, and the different modes of preparing it, and among which, the various experiments on this subject.
The machinery, required in gunpowder mills, is exceedingly simple. The power of the water, which may be given by an overshot, or undershot wheel, is communicated to the parts of the mill, which perform the work. Thus it is, that pounders, like the snuff, or plaster-paris mill, are put in motion, by a horizontal shaft, furnished, at different distances, with pieces of wood, which, by the revolution of the shaft, and meeting with the projecting pieces from the pounders, raises them in succession. They fall, then, in the same order of succession, in the respective mortars.
The mortars of the powder-mill, are hollow pieces of wood, capable of holding twenty pounds of paste, composed of the substances before mentioned, which are incorporated by means of the pestle. There are usually twenty-four mortars in each mill, where are made, each day, four hundred and eighty pounds of gunpowder; care being taken, to sprinkle the ingredients with water, from time to time, lest they should take fire. This precaution is absolutely necessary, and if attended to, would prevent many of the explosions, which, unhappily, take place, in the manufacture of powder. The friction must be great, and, therefore, the increase of temperature, occasioned in this manner, ought to be guarded against. This can only be done, by diminishing the time, or number of the blows, or by proportioning the weight of the pestle, and the frequent addition of water. The last is the most certain, and indeed, the water is in some respects, necessary to promote a more intimate mixture of the materials. The observations of M. David, on the use of water in the manufacture of powder, are certainly correct. The pestle is a piece of wood, ten feet high, and four and a half inches broad, armed at the bottom with a round piece of metal. It weighs about sixty pounds.
Having mentioned one cause of the explosion of powder-mills, that of friction produced by the pestle, we find that it has been accounted for on another principle. The Annales de Chimie, tome xxxv, mentions some instances of spontaneous combustion in powder mills. It is well known, that charcoal has the property of absorbing several gases, and the observations of Rouppe and Berthollet, on this subject, are conclusive. It is also known, that charcoal, which contains hydrogen, when exposed to atmospheric air, will absorb oxygen, and form water; and during this combination, heat must be generated, by the emission of caloric from the oxygen gas. It is said, then, that in cases of spontaneous combustion, when nitre, sulphur, and charcoal, are mixed together, (unless water be added to prevent it), this effect will ensue, and fire be produced. We know, however, that percussion is one source of heat; and in truth, if that opinion be well founded, percussion itself may facilitate the union of hydrogen, with the oxygen of the air, and necessarily operate as a secondary cause of such explosions.
Another opinion has been advanced by Bartholdi, to account for the spontaneous combustion in powder mills: namely, that charcoal sometimes contains phosphorus, combined with hydrogen, which, by the action of the pestle, is disengaged in the form of gas, and inflames, the moment it comes in contact with the air. Others again suppose, that it sometimes contains pyrophorus.
Pulverizing the charcoal, in the first instance, by itself, and adding water, during its mixture, from time to time, a measure proposed in 1808, by M. David, and now generally adopted, will prevent such accidents; for it appears, they have not occurred in France, since the adoption of this plan. Some remarks on spontaneous combustion, may be seen in the article on artificial volcanoes.
M. Sage, (Journal de Physique, vol. lxv, p. 423, or Nicholson's Journal, vol. xxiii, p. 277), has written on the spontaneous ignition of charcoal, and adduced some facts on the subject; by which it appears, that M. de Caussigni was the first, who observed, that charcoal was capable of being set on fire, by the pressure of mill stones.