Continuous process of carbon nanotubes synthesis by decomposition of methane using an arc-jet plasma

We present a method of producing carbon nanotubes by means of the thermal plasma decomposition of methane in an arc-jet plasma of high temperature (5000–20,000 K). Carbon nanotubes are produced under a floating condition by introducing methane and a mixture of Ni–Y powders into the arc-jet plasma flame generated by a non-transferred plasma torch. Material evaluations of the synthesized product by transmission electron microscopy (TEM) and scanning electron microscopy (SEM) reveal that the growth rate of carbon nanotubes is very high, and that the multi-walled carbon nanotubes of high purity are mainly produced. Since this process is continuously operable and easily scalable, it is expected to be a promising technique for large-scale commercial production of carbon nanotubes.