A pilot scale preparation of a-calcium sulfate hemihydrate (alpha-HH) from flue gas desulfurization (FGD) gypsum was conducted for the first time in mixed salt solutions under atmospheric pressure. The effects of salt solution recycling on the transition of alpha-HH from FGD gypsum were investigated by a comparison with that in laboratory scale, focusing on the dehydration rate of FGD gypsum, the crystal morphology, chemical composition and mechanical strength of the products. alpha-HH could be transformed from FGD gypsum in 3.5-6.0 h even though the salt solution was recycled seven times in laboratory tests and eight times in pilot tests. The product obtained in pilot scale has a purity of 95%and the alpha-HH crystals are mostly a prismatic morphology, with volume weighted mean diameter (D[3,4]) in the range of 52.9-84.0 mu m, 2 h bending strength of 5.6-6.2 MPa and 3d compressive strength of 15.7-25.3 MPa. The salt solution recycling achieves 56% recovery of salts in pilot scale and puts almost no negative impact on the product quality, which can be one of the best strategies to reduce the production cost. It is very likely that the process of salt solution recycling can be adopted in industry. (C) 2011 Elsevier B.V. All rights reserved.