Single-walled carbon nanotubes have been synthesized by the catalytic
decomposition of both carbon monoxide and ethylene over a supported metal
catalyst known to produce larger multi-walled nanotubes. Under certain
conditions, there is no termination of nanotube growth, and production
appears to be limited only by the diffusion of reactant gas through the
product nanotube mat that covers the catalyst. The present invention
concerns a catalyst-substrate system which promotes the growth of
nanotubes that are predominantly single-walled tubes in a specific size
range, rather than the large irregular-sized multi-walled carbon fibrils
that are known to grow from supported catalysts. With development of the
supported catalyst system to provide an effective means for production of
single-wall nanotubes, and further development of the catalyst geometry
to overcome the diffusion limitation, the present invention will allow
bulk catalytic production of predominantly single-wall carbon nanotubes
from metal catalysts located on a catalyst supporting surface.