Process for preparing catalyst composition for the synthesis of carbon nanotube with high yields using the spray pyrolysis method

A process for preparing catalyst composition having the apparent density of 0.01-0.50 g/ml for the synthesis of carbon nanotube in a high yield of 1,000-1,800% comprising the steps of:

• i) dissolving multi-component metal precursors of catalyst composition in deionized water;
• ii) spraying obtained catalytic metal precursor solution into the high temperature reactor by gas atomization method using 2-5 atm pressure of air;
• iii) forming the catalyst composition powder by pyrolysis of gas atomized material at the temperature in the range of 600-1,200° C.;
• and iv) obtaining the catalyst composition powder,
• wherein said catalyst composition is represented by following formula
• [Fea:Alb]x:My:Mgz;
• wherein
• Fe represents catalytic metal of iron or its oxide;
• Al represents catalytic metal of aluminum or its oxide;
• Mg represents inactive support of magnesium or its oxide;
• M represents at least one transition metal selected from Co, Ni, Cr, Mn, Mo, W, V, Sn, or Cu or its oxide;
• x, y, and z represent molar fraction of [the sum of Fe and Al], M, and Mg,
• wherein
• x+y+z=10, 2.0≦x≦8.0, 0.0≦y≦2.5, 0.5≦z≦8.0;
• a and b represent molar fraction of Fe and Al;
• a+b=10, 2.0≦a≦5.5, 4.5≦b≦8.0;
• and
• wherein said metal precursor is at least one selected from nitrate, sulfate, alkoxide and/or carbonate form of metal.