A continuous gas-phase method for producing single-wall carbon nanotubes
at high catalyst productivity and high yield is disclosed. The method
involves the use of a novel in-situ formed catalyst to initiate and grow
single-wall carbon nanotubes using a carbon-containing feedstock in a
high temperature and pressure process. The catalyst comprises
in-situ-generated transition metal particles in contact with
in-situ-generated refractory particles. The population of nucleating
sites for single-wall carbon nanotubes is enhanced due to the ease of
formation of a population of refractory particles. These, in turn,
improve the nucleation and stability of the transition metal particles
that grow on them. The larger number of transition metal particles
translate into a larger number of sites for single-wall carbon nanotube
production. The higher catalyst yields provide a means for obtaining
higher purity single-wall carbon nanotubes.