My experience has been that wet black powder, when dried , is just as live as it was originally.
Reading the Journal of the Lewis and Clark expedition I see that they spent a lot of time drying the powder after dumping the canoes and their contents in the river, apparently didn't adversely affect the product.
A friend in our local club was disposing of BP that had once been wet and since dried.
His method was to sprinkle it on a fire, he has healed nicely but it took some time.
The one thing I might be concerned about is that I have heard commercial PB has a coating that helps prevent BP from self igniting when compacted.
Phineas Gage comes to mind, if I remember correctly he was tamping BP in a hole for blasting, a spark was created, the tamping rod went through his cheekbone and out the top of his head, he lived but it changed his personality, I think he became a liberal.
Science teachers I have spoken with related that one needs to be careful as BP one makes oneself can spark when compressed.
Kind of like they told me at fireworks school, don't look down the tube, whether it is a 1.5 in. or a 12 in. mortor, they still come out about 200 MPH. So you have to take the rules by faith since when something goes wrong with this stuff, it goes real wrong, real fast.
My reading of the corning process is that it was created to prevent the component chemicals from separating in transit, than broken up to usable form at destination.
Thank you for responding, I did want to hash this over with someone. I know that BP is "stuck" on the end of Pyrodex pellets to get it to light, Maybe isopropol alcohol would help bind it temporarily and then dry out.
I have found a cake decorating tube that I might adapt to extrude the mixture.