Some figures from Lyman's most recent "Black Powder Manual & Loading Handbook":
Muzzle velocity for .54 PRB over 90 Gr. Goex FFG:
24" 1:48 barrel: 1567 fps
28" 1:48 barrel: 1555 fps
32" 1:60 barrel: 1480 fps
Loads from 70 to 110 Gr. showed a similar drop-off
Muzzle velocity for .54 PRB over 90 Gr. Pyrodex RS:
24" 1:48 barrel: 1561 fps
28" 1:48 barrel: 1626 fps
32" 1:60 barrel: 1628 fps
Muzzle velocity for .50 PRB over 90 Gr. Goex FFG:
24" 1:48 barrel: 1580 fps
28" 1:48 barrel: 1651 fps
32" 1:60 barrel: 1768 fps
This shows good gain with barrel length
Muzzle velocity for .50 PRB over 90 Gr. Pyrodex RS:
24" 1:48 barrel: 1664 fps
28" 1:48 barrel: 1725 fps
32" 1:60 barrel: 1768 fps
There appears to be some gain with increasing barrel length, but not always. Seems to depend on the load and the caliber....probably the barrel as well.
For a .54 with moderate loads of RS, it seems you reach a point of diminishing returns somewhere near 28". Heavy loads of FFG(120Gr.) show significant gain from 28" to 32", but the 24" barrel velocities are about halfway between those for the two longer barrels...
I'm with Old School. When it comes to barrels over 36 inches; I don't get it. Seems like 32" delivers about all you can reasonably expect.
Bob