This article deals with the investigations on mullite ceramics formation from Kyanite sample- an alumino-silicate mineral with microwave heating. In the present investigation kyanite was heated in microwave sintering furnace with calcined alumina, silicon carbide, zirconium dioxide and binder for mullite formation as well as for the preparation of zirconia toughened mullite product. The results of these studies reveal that how a small amount of zirconium dioxide helps in toughening the mullite formation for refractory and ceramics applications. The results shows that microwave heating method is one of the most novel and eco-friendly process for such toughened mullite formation, well within very short period of time. The observations with mullite formation and zirconia toughened mullite formation were observed with the structural data using X-ray diffraction data, field effect scanning electron microscope and energy dispersive spectroscopy. Future studies are still in process.