Hello all,
I spent about 6 months volunteering at the California Academy of Sciences Steinhart Aquarium in the Aquatic Husbandry Department. I worked on the coldwater marine systems there including a large grouper tank, giant pacific octopus tank, rocky reef tank, and of course the 100,000 California Coast Tank. I did this because I was curious to see how these aquariums were built behind the scenes in order to see if I could bring some of the concepts back to home aquaria. It was a great experience and I learned a lot.
Nonetheless, I feel I can help you with a few of the questions.
Glass will not work for a tank this big; acrylic panels (at least a foot thick) will be the only option. The rest of the tank will be reinforced concrete, preferably excavated into the ground, along with a sealant of which there are many.
Sumps for these tanks will either be reinforced fiberglass, or more likely for an 80,000gal system, concrete cisterns built into the ground on the scale of thousands of gallons.
MRC makes industrial sized skimmers, so does Aquarium Engineering which is Bill Wann's company. Get yours from Bill!
Lighting should be a combination of natural, metal halide, and it seems like LED's may be feasible now too.
Flow for a tank this big has only one option. The Hydrowizards is basically a huge prop pump. They used three of these on the 100,000 Cal Coast tank. From
http://www.belowwater.com/category/pump/
Temp control can only be achieved with industrial size heat exchangers.
We fed a combo of fresh seafood like capelin and other small fish. We also fed what I can only describe as a "protein block" of food. It was sorta spongy and supposedly had lots of vitamins and other stuff.
Water changes can be performed by running to large cisterns in parallel that can be isolated. When you want to do a water change, fill the offline cistern with fresh saltwater, then redirect flow to this cistern. Drain the other cistern. Alternate order for next water change.
Best,
Kent