Abstract: A proppant is formed by a method including inserting a plurality of particles into a heating device, such as a rotary tunnel kiln. The particles are heated at a first temperature within the heating device. A non-epoxy, non-urethane thermoset coating is heated to at least its melting point or dissolved in a solvent or both, and sprayed into the heating device and onto the particles. The particles are heated to a second temperature, higher than the first temperature.