This study aims to improve the understanding of formation of mullite from kaolin at low process temperature using different sintering regimes. The optimum parameters affecting mullite formation from kaolin such as sintering temperature (from 1000 to 1500 degreesC), heating rate (3 and 20 degreesC min(-1)) and dwell time (3 min, 1 and 5 h) were investigated. There was a marked increase in bulk density values with increasing sintering temperature up to similar to1300 degreesC, resulting in a significant decline at the apparent porosity values. The lower heating rate and the longest dwell time appeared to be more effective to obtain a maximum density value at 1300 degreesC. Microstructural features were examined using SEM, and the nature of crystalline phases present was confirmed by XRD analysis. It was observed that formation of mullite grains started at similar to1100 degreesC. Although there was a significant amount of mullite grains at 1200 degreesC, completely elongated mullite crystals were formed at 1300 degreesC.