Extrapolating the properties of individual CNTs into macro-scale CNT materials using a continuous and cost effective process offers enormous potential for a variety of applications.The floating catalyst chemical vapor deposition (FCCVD) method discussed in this paper bridges the gap between generating nano-and macro-scale CNT material and has already been adopted by industry for exploitation. A deep understanding of the phenomena occurring within the FCCVD reactor is thereby key to producing the desired CNT product and successfully scaling up the process further. This paper correlates information on decomposition of reactants, axial catalyst nanoparticle dynamics and the morphology of the resultant CNTs and shows how these are strongly related to the temperature and chemical availability within the reactor. For the first time, in-situ measurements of catalyst particle size distributions coupled with reactant decomposition profiles and a detailed axial SEM study of formed CNT materials reveal specific domains that have important implications for scale-up.A novel observation is the formation, disappearance and reformation of catalyst nanoparticles along the reactor axis, caused by their evaporation and re-condensation and mapping of different CNT morphologies as a result of this process.

The floating catalyst chemical vapor deposition (FC-CVD) process permits macro-scale assembly of nanoscale materials, enabling continuous production of carbon nanotube (CNT) aerogels. Despite the intensive research in the field, fundamental uncertainties remain regarding how catalyst particle dynamics within the system influence the CNT aerogel formation, thus limiting effective scale-up. While aerogel formation in FC-CVD reactors requires a catalyst (typically iron, Fe) and a promotor (typically sulfur, S), their synergistic roles are not fully understood. This paper presents a paradigm shift in the understanding of the role of S in the process with new experimental studies identifying that S lowers the nucleation barrier of the catalyst nanoparticles. Furthermore, CNT aerogel formation requires a critical threshold of FexCy > 160 mg/m3, but is surprisingly independent of the initial catalyst diameter or number concentration. The robustness of the critical catalyst mass concentration principle is proved further by producing CNTs using alternative catalyst systems; Fe nanoparticles from a plasma spark generator and cobaltocene and nickelocene precursors. This finding provides evidence that low-cost and high throughput CNT aerogel routes may be achieved by decoupled and enhanced catalyst production and control, opening up new possibilities for large-scale CNT synthesis.

The floating catalyst chemical vapour deposition (FC-CVD) method is unique in providing the capability for continuous carbon nanotube (CNT) synthesis at an industrial scale from a one-step continuous gas-phase process. Controlling the formation of the iron-based catalyst nanoparticles is widely recognized as a primary parameter in optimizing both CNT product properties and production rate. Herein the combined influences of pyrolytic carbon species and catalytic nanoparticles are both shown to influence CNT aerogel formation. This work studies the source of carbon in the formed CNTs, the location of aerogel formation, the in-situ behaviour of catalyst nanoparticles and the correlated morphology of the resultant CNTs.Axial measurements using isotopically-labelled methane (CH 4 ) demonstrate that carbon within all CNTs is primarily derived from CH 4 rather than some of the early-forming CNTs being predominantly supplied with carbon via thermal decomposition of catalytic precursor components. Quantification of CNT production along the axis of the reactor definitively 2 dispels the notion that injection parameters influence CNT formation and instead shows that bulk CNT formation occurs near the reactor exit regardless of the carbon source (CH 4 , toluene or ethanol). Supply of carbon to different reactor locations indicates that CNT aerogel formation will occur even when carbon is delivered near the exit of the reactor so long as the carbon source reaches a sufficient temperature (>1000 °C) to induce pyrolysis. These results give an indication of how future large-scale CNT reactors may be optimized and controlled by modifying downstream catalyst and carbon delivery.

The agglomeration and self‐assembly of gas‐phase 1D materials in anthropogenic and natural systems dictate their resulting nanoscale morphology, multiscale hierarchy, and ultimate macroscale properties. Brownian motion induces collisions, upon which 1D materials often restructure to form bundles and can lead to aerogels. Herein, the first results of collision rates for 1D nanomaterials undergoing thermal transport are presented. The Langevin dynamic simulations of nanotube rotation and translation demonstrate that the collision kernels for rigid nanotubes or nanorods are ≈10 times greater than spherical systems. Resulting reduced order equations allow straightforward calculation of the physical parameters to determine the collision kernel for straight and curved 1D materials from 102 to 106 nm length. The collision kernels of curved 1D structures increase ≈1.3 times for long (>102 nm), and ≈5 times for short (≈102 nm) relative to rigid materials. Applications of collision frequencies allow the first kinetic analysis of aerogel self‐assembly from gas‐phase carbon nanotubes (CNTs). The timescales for CNT collision and bundle formation (0.3–42 s) agree with empirical residence times in CNT reactors (3–15 s). These results provide insights into the CNT length, number, and timescales required for aerogel formation, which bolsters our understanding of mass‐produced 1D aerogel materials.