My understanding of the modern BP manufacturing process is that the Charcoal, Sulphur and Potassium Nitrate are combined in a slurry with water or alcohol so it cannot separate, Then the slurry is dried, crushed to fine particles then passed through a series of sieves to sort into the various size particles. Then a bit of graphite is added to improve pourability and reduce static cling. BTW, there have been many experiments by the National Muzzle Loading Rifle Association to ignite BP by an electrical spark and all have failed - urban myth. My understanding of the physics is that the carbon in the BP conducts the electrical charge so easily (no heat-causing resistance like in a stove element or toaster) that the powder doesn't reach ignition temperature.
http://www.ctmuzzleloaders.com/ctml_experiments/sparks/sparks.html




























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