A novel in situ approach to mass fabrication of carbon nanotubes was reported. Composites of polypropylene (PP)/organomontmorillonite (OMMT)/nickel formate (NF) were prepared by mixing these components in a Brabender mixer at an elevated temperature. Chestnut-like carbon nanotube (CNT) spheres were in situ fabricated in high yields by heating the PP/OMMT/NF composites at 900 degrees C without adding any additional pre-synthesized nickel nanocatalysts. The products were studied by X-ray diffractometer (XRD), transmission electron microscopy (TEM), scanning electron microscopy (SEM), Raman spectroscopy, and N-2 adsorption-desorption measurements. The results showed that nickel nanoparticles were in situ produced, which catalyzed the formation of multiwalled carbon nanotubes (MWNTs) in an autoclave-like microreactor formed by OMMT. These in situ formed nickel nanoparticles were found to be more catalytically active than pre-synthesized nickel nanocatalysts, resulting in higher yields of CNTs. The obtained CNT spheres have a high surface area, which makes them a good catalyst support. Loading of metal nanoparticles was preliminarily tried, and Pt nanoparticles of ca. 2.65 nm in size were successfully deposited on CNTs. The applications of these nanocatalysts in chemical reactions are currently being studied in our laboratory.