Ultra-pure single wall carbon nanotube fibres continuously spun without promoter

We report a new strategy towards the control of carbon nanotube (CNT) structure and continuous fibre formation using a floating catalyst direct spinning CVD process. In the procedures used to date, a sulphur promoter precursor is added to significantly enhance the rate of CNT formation in the floating catalyst synthesis. Within the reaction zone, the rapidly grown nanotubes self-assemble into bundles, followed by their continuous spinning into fibres, yarns, films or tapes. In this paper we demonstrate a catalyst control strategy in the floating catalyst system, where the CNT formation process is independent of the presence of a promoter but leads to successful spinning of the macroscopic carbon nanotube assemblies with specific morphology, high purity (Raman D/G 0.03) and very narrow diameter range (0.8–2.5 nm). This can be achieved by the control of catalyst precursor decomposition and subsequent formation of homogeneous nano-sized catalyst particles.