Any idea what the white crystalline substance would have been then? Google searches suggested to me it was KNO3. I'd hate for it to have been something particularly volatile along the lines of nitroglycerin that I was applying force to remove the cap on the measure.
Well, that's where I was going with it. There would only be minimal amounts of K or Na in it, as I mentioned before, and I don't
think any IMR powders are double-based, that is, have nitroglycerin in them. Burning rate is primarily controlled by granule size, hole-in-the-middle size, graphite, loading density, and deterrents.
There is minimal amounts of other stuff like preservatives and stabilizers, and a bit of residual ether-alcohol solvents, none of which would imply the amount of gunk you are describing.
The only other thing I can think of (per brimic's suggestion) is some kind of galvanic reaction between your aluminum foil (was that you?) under the cap with high humidity or something like that.
Well.... or... do you have a male cat? They do weird things. (I'm not really kidding.)
Terry