Often powders which are slow or don't burn cleanly leave behind molten particles that melt plastics. After milling my willow meal for 2 hours, I can light a couple of grams on a piece of paper with only small scorch marks.
What colour is the powder left behind?
*White spherical droplets usually indicated potassium nitrate is not being consumed, caused by either incorrect weights (over oxidised), not ground fine enough, or impure potassium nitrate.
*Burnt/blackened remenants mean the powder isn't burning cleanly, has too much fuel, or hasnt been ground fine enough.
*Any other colour usually indicates an impurity. A while back there was a post on red residue left, and it was found to be a problem with the potassium nitrate.
Judging by the granule size you mentioned, I'd say you need to try grinding better.
You could try taking a sample of about 1g of your existing powder, and grinding it really well for 20 minutes or longer in your mortar and pestle. Test this and compare the residue to the one before. If it burns much more cleanly then I think you've solved the problem.
Edited by pyromaniac303, 22 April 2009 - 09:37 PM.
You can never have a long enough fuse...