The CIA Connection

Introduction

There is a certain popular mythology surrounding the contents of this chapter. The myths re-volve around "secret" methods developed for CIA and other clandestine field operators. These methods would enable such persons to quickly formulate concoctions to blow up various as-sortments of baddies, all in the name of freedom, democracy and making the world a better and safer place to live in.

Such heroes, armed only with their wits and a Swiss army knife, would thus be able to do what others considered to be nothing short of the miraculous. And, wonder of wonders, their secrets have finally been released into the public domain. The truth is somewhat less romantic.

This chapter describes one of a series of studies initiated by the Frankford arsenal way back in the sixties. These studies investigated methods whereby US armed forces would be able to manufacture and use improvised weaponry in the field. It really had nothing to do with the CIA. This chapter has emulated the way that the original data was presented and thus its lay-out and format differs somewhat from the rest of the book.

This so-called "CIA method" attracted many pyrotechnic enthusiasts (pyros) who had wanted to try their hands at making their own Black Powder but had often been disappointed and frus-trated in their efforts. While this method gave improved results to some, it was not quite what many pyros hoped it would be.

Results of my own personal attempts were also disappointing. Although I achieved a jump in performance over simple hand-ground Black Powder, the CIA method powder did not even come close to powder needed to eject the stars in my Roman candles. Yes, it did burn faster. In fact it burned at a linear burn rate of five times that of the hand-ground powder! This was no mean feat in itself, but it was still not fast enough.

I discussed my findings and frustrations with others and learned that their experiences were similar to mine. My burning speed had hit a ceiling of about 15 centimeters per second (cm/sec.). Theirs had too. Were we all doing something wrong? Yes we were. We were all wrong to buy into the notion that acceptable Black Powder could be made without proper milling and incorporation.

Reading carefully between the lines in the official descriptions of the CIA method reveals that proper milling and incorporation is recommended. Of course, under field expedient conditions this may not always be possible. Maybe for this reason the milling and incorporation stage has been downplayed. Unfortunately, it has been downplayed to the extent that many have tried the CIA method using ingredients that have been poorly milled and incorporated. Their results have naturally been disappointing.

So the CIA method has gotten a bad press. And some have gone on their own personal jihads to try and discredit it in any way they can. Some of these same individuals may even find this book hopelessly flawed because it devotes a whole chapter (and a long one at that) to the CIA method.

The CIA method does have its drawbacks. These are discussed both in this chapter and in

other chapters of this book. It does, however, offer some advantages that other methods do not.

The CIA method:

• Offers a viable entry-level method to those starting out in making Black Powder.

• Does not require special machines or equipment (for slower powders).

• Does not have the explosion hazard of some other methods.

The CIA method, when it is combined with ball milling, can produce a Black Powder that is more than adequate for use as a propellant. This has been proven by both myself and experi-menters all over the world with whom I have been corresponding over the years.

What follows in the rest of this chapter is the traditional CIA method text, gleaned from the original government reports. After this I have added my own tested and proven methods for im-proving the CIA method, together with ball milling to yield a very fast powder. An honest at-tempt is also made to point out deficiencies and drawbacks in the CIA method.

Approach

The following sequence was pursued in the Black Powder study:

• Literature survey.

• Evaluation of techniques for the preparation of Black Powder.

• Performance evaluation of various preparations.

• Preparation of a field manual outlining preparation procedure(s).

Discussion

The fact that Black Powder has been known to exist for some 2,000 years does not necessarily imply its current mode of preparation is particularly simple. Although a great number of inves-tigators have independently studied and prepared Black Powders, all procedures that have re-sulted in satisfactory products are somewhat involved with respect to the incorporation steps.

Simple mixing techniques of either dry or moist ingredients invariably result in inferior prod-ucts. The purpose of the current program has been the establishment of a method, or methods, for the preparation of suitable Black Powders which may be accomplished by novice personnel using simple, readily obtainable implements.

A number of basic parameters are all important in the successful blending of Black Powder.

Initially, the sulfur must be intimately incorporated into the cellular structure of the carbon which is usually accomplished by ball milling. Subsequently, the nitrate is mixed with the fuel mixture and requires pressure milling (while moist) in order to achieve proper intimacy. Failure to attain the proper degree of incorporation of the ingredients invariably results in inferior products.

The initial phase of the program dealt with possible means by which the commercial methods could be converted, at least in part, to field expedient procedures. These studies resulted in poor to mediocre products, and inconsistent results were the rule rather than the exception.

The lack of any significant degree of success is attributed to substitution of inferior equipment in the operation and lack of experience required throughout the process.

Of necessity, a method meeting the design criteria of the current program must employ avail-able utensils, and require a very limited degree of practice or instruction. This would dictate that principles of preparation be unaffected by a broad range of variation in the procedure, or

be a procedure of ultimate simplicity. This goal was achieved through the investigation and de-velopment of a unique precipitation procedure. Essentially, this method consists of preparing a hot slurry of charcoal and sulfur suspended in concentrated aqueous potassium nitrate with the subsequent precipitation of Black Powder by rapid drowning in a common organic solvent such as isopropanol. From this point, filtration, granulation, and drying were facile rapid proc-esses. The resulting products were generally consistent from lot to lot, and approached com-mercial powders in performance. The method and powder performance test results are consid-ered adequate fulfillment of the requirements of the program.

For illustrative purposes, a flow chart comparing the precipitation method and a typical com-mercial procedure are shown below. As indicated on the chart, comcom-mercial methods involve working with Black Powders containing 4% moisture, or less, with the corning mill step being considered the most hazardous of the operations. By contrast, the precipitation method does not involve working with a low moisture content material until the final product is obtained.

A comparison of the burning rates of the various lots of Black Powders prepared during the program is presented in Table 7-1. Lots 1 through 6 represent the powders prepared initially involving the most conventional preparative techniques, while Lots 7 through 14 are powders produced by the precipitation method.

Experimental

All approaches to the preparation of Black Powders emphasized simplicity. Initial studies were a modification of techniques which essentially followed the principles used in commercial pro-cedures. This included methods for incorporating sulfur with charcoal, subsequent incorpora-tion of nitrate with the blended fuel and pressing operaincorpora-tions. Attempts to use field expedient means to simulate commercial Black Powder processes resulted in products exhibiting poor to fair performance. Realization of the difficulties being encountered in this approach prompted investigation of other means of blending the ingredients, and led to precipitation techniques which offer a simple, novel solution to the problem. The ultimate method chosen involved sol-vent precipitation of Black Powder from a hot, aqueous, concentrated potassium nitrate solu-tion containing suspended charcoal and sulfur. Common organic liquids such as methanol, 70% isopropanol (rubbing alcohol) and 80 proof ethanol (vodka) successfully served this pur-pose. The pyrotechnic properties of Black Powder prepared in this fashion approached those of commercial Black Powder.

Simplicity and safety are inherent in the method since no extensive premixing operations are required and the mixture can be handled in a moist form throughout the preparation. It is noteworthy that the method is independent of the prior particle form of the potassium nitrate since total solution of the salt is attained in the procedure. In addition, essentially reproducible products are obtained by this method as compared to the less effective methods initially inves-tigated.

The overall experimental work and results are described in the subsequent portion of this sec-tion. The description of the work is divided into three sections: an initial portion concerning the more conventional hand mixing techniques, a second section pertaining to the precipitation method, and a final section reporting field application of powders.

Charcoal +