You can make perfectly serviceable BP without a ball mill. Grinding in a pestle and mortar is risky, but probably OK for <1g batches with the appropriate safety gear. However, if you want to make a usable quantity, even 10g, you will find that a pestle and mortar is not only unsafe, but also pretty hard, dull work. However, you can make usable BP quickly and easily by the precipitation method. There is a good description of this in ?Introductory Practical Pyrotechnics,? but if you don?t have this, there is a good procedure on
Wouter Visser's page. There are some changes I would recommend though:
2. I?d just use 15g of C and 10g of S, and you can then powder these in a together coffee grinder or pestle and mortar. Grinding this mixture like this is OK, since there is no oxidiser. (The potassium nitrate does not need to be powdered, since it will be completely dissolved in the boiling water).
3. Obviously you will need 150ml of alcohol. Any reasonably pure kind will do ? methylated spirit is fine.
Finally, do not do this inside. I know it?s obvious, but Wouter doesn?t mention it. The powder grains that result will be quite fragile, and the powder won?t be as fast burning as ball milled powder, but if you use a little more of it that shouldn?t be a problem. The Maltese make a lot of their powder like this, without ball mills or presses.