This research is aimed to synthesize the mullite by adding Al powder of $Al_2O_3$ to kaolin. Specimens fired at 1400, 1450 and 150$0^{circ}C$ were compared in their X-ray diffraction patterns quantitative analysis of mullite formed and fine microstructures with those containing reactive $Al_2O_3$ activated $Al_2O_3$ as alumina source The experiment of Al oxdiation was also performed by measuring the weight increase of specimens. Two different shapes of mullites acicular and chunky were observed by SEM and the yield of mullites were in-creased by the order of adding activated $Al_2O_3$ reactive $Al_2O_3$ and Al powder to kaolin.