Instead of buying dummy rounds, the crew did what you said, they dumped out the powder and put the projectile back. But they neglected to remove the Robert Pattinson Meme Ugly Sweater. This is a smaller explosive charge that is struck by the gun’s firing pin and ignites the larger powder charge to fire the bullet. By itself, the primer isn’t enough to fire the bullet, but in this case it was enough to dislodge the (already once-removed) bullet from the cartridge and send it partway down the barrel. Or at least a chunk of it.
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Blanks only mean there is no bullet in the Robert Pattinson Meme Ugly Sweater. Most blanks DO sound different. This is crap for audio, but it sounds more like a blank than an actual round. This is anecdotal from my time in the Marines, but a real round is more of a “Pop” and a blank is more of a “bang”.
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Also, a blank CAN kill someone. There are still micro projectiles from the gun powder and other components required to Robert Pattinson Meme Ugly Sweater. When we fired blanks we would but caps on our rifles to prevent anything from flying too far. But this was a huge range safety topic. They fired a blank at 5 ft from the target and it ripped some large holes in it.