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In this work, the effect of inclusion of nanographite particles in a polypropylene (PP) matrix is studied. Nanographite particles were obtained through ultrasound exfoliation from graphite upon using a water-based hydrophobically modified alkali-swellable emulsion (HASE) associative polymer as a surfactant. Results indicate that exfoliation renders particle size distribution ranging from 3 to 3000 nanometers. Nanographite was blended with PP through two extrusion processes: twin screw and single screw, the latter includes the coupling to a static-mixer head, to generate extensional flows. Concurrently, ultrasonic waves are applied to the molten flow through ultrasonic transducers attached to the mixing head, which induces high particle dispersion and good particle distribution in the polymer matrix. It was found that at HASE concentration of 5% by weight and sonication time of 14 days (period of the exfoliation process), optimum tensile properties of the compound were achieved. Also, with respect to the PP matrix, the rate of thermal degradation decreased from 2.1 (PP) to 1.9 (% °C−1), melt temperature ranged from 442°C (PP) to 396°C, and melt index decreased from 7.4 (PP) to 6.2 (g/10 min). Raman spectroscopy confirmed the exfoliation process, rendering sizes ranged from graphite particles of few graphene layers to micron-sized particles. Rheological measurements of the compounds revealed that the extrusion-ultrasound process influences the viscosity, storage, and loss moduli. The dispersion and distribution of nanoparticles improved the electromagnetic radiation shield (approximately 35%). The dielectric constant changed from 2.21 (pristine PP) to 9.02 for the compounds, which enables a good level of electrostatic charge dissipation.

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