Methods, processes, and apparatuses for the large scale synthesis of carbon nanostructures are provided. The apparatus for continuous large scale production of SWNTs includes a chamber. Positioned in one end of the chamber is a piston and at the other end is a tangential vortex created by gases forced into the chamber from opposite sides of the chamber walls. The chamber can be heated to reduce or eliminate agglomeration of small particles. The piston is used to push the catalyst towards the vortex, and the injection rate is controlled by the speed of the piston and the gas flow rate to create the vortex that also act as the transport gas. Thus, greater than 1 kg/h of an aerosolized, deagglomerated dry powder catalyst can be delivered to the reactor at a constant flow rate.