Big Basic Change #1 - Screen Size
Originally, the standard method used to calculate the screen size required was based on the size of the tank. Around September 2011, that method was revised to be based on feeding amount. This is a very important change, because not only does it mean an Algae Scrubber screen is more appropriately sized, it also means you will get better growth results. As it turns out, bigger is not necessarily better when it comes to your algae screen – the algae on a screen that is too large compared to the amount being fed will become nutrient deficient over time as the algae will want to grow across the entire screen. Concentrating this algae growth down to the appropriate size in accordance with the amount fed means you will typically get more green growth, and green hair algae is what filters the best (and smells the least, I might add).
The good news here is that this means that in most cases, you can get away with a significantly smaller screen, and guesstimating your bio-load specific to your system is completely unnecessary.
Once you figure out your available flow, then it's time to figure out your optimal screen dimensions.
There are 2 ways of looking at this: square inches based on length and width dimension, and square inches based on illuminated surface area. The latter is technically more accurate, but since most people light both sides, the former is usually referenced.
The new rule is based on cube-equivalent amount of food fed daily, regardless of how many gallons you have in the system. You need 12 square inches of screen illuminated on BOTH SIDES with a total of 12 watts of fluorescent light for 18 hours/day for each cube-equivalent fed into the system per day. That means 6 watts per side of real wattage, not equivalent wattage. LED wattage is addressed separately as it has a different set of rules.
The cube-equivalent is defined as any ONE of the following:
1 frozen cube
10 pinches of flake food
10 square inches (60 sq cm) of nori
0.1 dry ounce (2.8 grams) of pellet food
3.25 mL of liquid coral food
If you feed something else and are having a hard time determining the cube-equivalent, then take the daily amount of food, put it in a blender with some water and puree it well, then strain it using a coffee filter (or a rotifer sieve if you happen to have a spare one laying around) and pour the food into an empty Ocean Nutrition or other cube-type food tray, and you will have the cube-equivalent for that amount of food.
If you light the screen from only one side, double the dimensional measurement of the screen; light requirement is the same, it’s just all on one side.
For a non-vertical screen, double the dimensional measurement again. Any screen that is not 100% vertical is treated as a horizontal screen (even if it’s only slightly slanted). This is because of the channeling properties inherent to a slanted or horizontal screen; there is an immediate loss of efficiency when the screen is non-vertical.
So, just so we're 100% clear on this:
Vertical, lit from both sides: 12 square inches of screen material per cube of food per day, 12 watts of light split between each side.
Vertical, lit from only one side: 24 square inches of screen material per cube of food per day, 12 watts of light on one side.
Non-vertical: 48 square inches of screen material per cube of food per day. Lighting must increase by a factor of 1.5 (discussed in the lighting section). In this case, a MINIMUM of 18 watts of light is needed, preferably much, much more.
Screen Dimensions
So now that you know your actual flow rate AND the necessary size of your screen (dimensional area), now you are ready to figure out your dimensions.
You want the flow to be a minimum of 35 GPH per inch of screen width. You can get by with a lower flow rate, but your Algae Scrubber may not be strong enough depending on your bio-load. You can have higher flow also, which is generally not a problem as long as your screen is rough enough and you aren’t getting black slime algae (which is a sign of high nutrients, and needs more frequent cleaning until it lightens up). What you want to achieve is enough flow so that you have a full sheet of water across the screen off the bottom edge, like this:
Simply take your GPH (that you just measured) and divide by 35, and this will be your maximum screen width. Then, take that number and divide it into your total screen area to obtain the height dimension of the screen. The result is the total area of roughed-up screen that you want.
You want to add to the height dimension for the section of smooth screen that will be inserted into the slot pipe. You want to allow for the distance that the screen will be inserted into the slot pipe, plus at least 1/8" of smooth screen below the slot tube to help prevent algae growth into the slot. The total amount of smooth screen you need depends on how far you insert the screen into the slot pipe. A little extra smooth screen at the top never hurts, as it can be trimmed off later if you leave too much.
You may also want to leave smooth screen at the bottom as well. Most screens, in some form or another, will ‘dip’ into a pool of water at the bottom. This submerged area does not grow algae very well, so you can leave that smooth too.
The critical area, and the only area that contributes to scrubbing power, is the roughed-up and illuminated portion of the screen. Figure out your necessary screen dimensions, and then add the extra smooth sections to the height dimension.
If the only way you can mount your scrubber is to have it hanging in free air and high above your sump, you can leave a significant amount of smooth screen below the ‘effective’ area, or you can attach another screen to the bottom edge of the main screen. You may end up with some gooey growth on this screen though, so you should avoid it if possible (IMO).