Polyaniline (PANI)/graphene composites were prepared by the in-situ polymerization of aniline in a 1 M aqueous solution of methanesulfonic acid (MSA) containing graphene, which was prepared separately from graphite powders by simple sonication in MSA. Graphite powders spontaneously exfoliated to form graphene (GPM), which was then quenched with excess water, filtered, and dried to produce powders. The dried graphene powders produced were re-dispersed well in a 1 M MSA aqueous solution, in which the in-situ polymerization of aniline was performed. The resulting PANI/GPM composite had a conducting emeraldine salt (ES) form, and showed good electrical and thermal properties, compared to pure PANI prepared using a 1 M HCl solution. The PANI/GPM composite could be dissolved in a MSA solution and spin-coated in a conducting ES form of PANI. In contrast, the ES form produced from a HCl solution was insoluble in organic solvents and needed to be reduced to convert it to the emeraldine base form to produce a PANI solution. Therefore, the in-situ preparation of PANI/graphene composites using MSA provides a facile means of improving the thermal and electrical properties of PANI and its processability. (C) 2014 Elsevier Ltd. All rights reserved.