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Abstract

A chemical precursor mediated process was used to form catalyst nanoparticles (NPs) with an extremely high density (1014 to 1016 m−2), controllable size distribution (3−20 nm), and good thermal stability at high temperature (900 °C). This used metal cations deposited in layered double hydroxides (LDHs) to give metal catalyst NPs by reduction. The key was that the LDHs had their intercalated anions selected and exchanged by guest−host chemistry to prevent sintering of the metal NPs, and there was minimal sintering even at 900 °C. Metal NPs on MoO42− intercalated Fe/Mg/Al LDH flakes were successfully used as the catalyst for the double helix growth of single-walled carbon nanotube arrays. The process provides a general method to fabricate thermally stable metal NPs catalysts with the desired size and density for catalysis and materials science.