Methods, processes, and apparatuses for the continuous synthesis of carbon nanostructures are provided. Metal catalysts having small diameter and narrow distribution of particle sizes are prepared and continuously injected as aerosols into a reactor. The metal catalysts are supported on supports that are substantially free of carbon. The metal catalyst, in the form of a powder, is placed on a fluidized bed and aerosolized using an inert gas. The powder entrailed in the gas is injected near the top of a vertical reactor for the synthesis of SWNTs.