Screen Size
Once you figure out your flow point, 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.
For every gallon of water in your display tank, you need 2
total square inches of illuminated screen material. This means that if you run a screen that is vertical and lit from both sides, then you need a screen with dimensions (length times width) that is equal to the size of your tank, or
1 square inch of material per gallon. This is what you will see commonly referenced, and what I continue to reference for simplicity's sake. Double the dimensional measurement for a vertical screen, lit from only one side. Double it again for a horizontal or slanted screen.
Sizing of the screen does not require inclusion of the volume of water in the sump. Note that this is a correction from most of what has been posted previously (even by me - oops).
So, just so we're 100% clear on this:
Vertical, lit from both sides:
1 square inch of screen material per gallon (
2 square inches of illuminated screen area per gallon)
Vertical, lit from only one side:
2 square inches of screen material per gallon (which is
also 2 square inches of illuminated screen area per gallon)
Horizontal:
4 square inches of screen material per gallon (
4 square inches of illuminated screen material per gallon). Lighting must increase also (noted below). Also note that
this is a correction to what was listed on Post #1 of this thread (that post listed that a 10 x 10 screen was good for 40 gallons, instead of 25 gallons)
Screen Dimensions
So now that you know your actual flow rate AND the total size of your screen (and you need to know the total dimensional area for this part, not the total surface area), now you are ready to figure out your dimensions.
You want
35 GPH per inch of screen width. Simply take your GPH (that you just measured) and divide by 35, and this will be your optimal screen width. Then, take that number and divide it into the gallon size of your display tank to obtain the height dimension of the screen. Use the
size of your tank, not the gallons that you think are actually in it (so do not account for volume of Live Rock, fish, decor, etc) and do not include your sump volume. The result is the total area of roughed-up screen that you want.
In general, you want to add at least one inch to the height dimension for the section of smooth screen that will be inserted into the slot tube. Specifically, you want to allow for the distance that the screen will be inserted into the slot, plus at least 1/4" of smooth screen below the slot tube to help prevent algae growth into the slot, so this "one inch" is just a good rule of thumb, and should be increased depending on the diameter of your slot tube. A little extra smooth screen at the top never hurts.
The critical area, and the only area that contributes to scrubbing power,
is the roughed-up and illuminated portion of the screen.
Pipe
As far as pipe diameter is concerned, just match the size of the drain pipe that you currently use. If you're doing a pump fed scrubber, either top of tank or sump, try to match the feed tubing and components to the recommendations from the pump manufacturer.
The slot tube itself should be
Schedule 40 PVC at a minimum.
Don't use vent pipe, flexible hose, or thin-walled PVC. The reason is that cutting a slot in the tube weakens it enough that it can bow over time and cause the slot to change width. This is especially true for a large scrubber. Anything over 24" should probably have 2 slots, with a small section in the center left uncut (maybe 1/4") with some kind of means of support at the center.
pic of yesman's scrubber (from the algae scrubber site)
I'm not saying that it won't work, and I'm not critiquing the design pictured above. It just got me thinking that it can't be good to have that pipe flexing that much. So this is a new recommendation I am making for scrubbers with screens over 24" wide. But check out that growth!!! That's
6.5 pounds of algae (drained).
Cutting the Slot
This arguably the most difficult part of building a scrubber.
The width of the slot should be approximately 1/8" wide, the same length as the screen which you are using (as exact as possible), and as straight as possible. The best way to cut the slot straight is by using a table saw, and being very careful. Since most people don't have access to a table saw (or aren't very careful), a dremel with a cutoff wheel it the most popular way of cutting the slot. This takes time and patience. Mark the slot, and cut carefully.
If you mess up, do it again. PVC pipe is cheap. Once you solvent weld it and endcap and a union to it, it is not as cheap to replace (but still relatively cheap)
From the Algae Scrubber site (also posted in this thread)
Screening Material
The search for the "perfect material" for growing algae in the vertical waterfall configuration has always come back to the same material, the
#7 Mesh Plastic Canvas, roughed up with a
hole saw or a rasp. You can feel free to experiment, but this material has been proven to work over and over again.
A new screen is slick and smooth. It needs to be roughed up so that the algae has anchoring points. Once the screen is established, algae can grow very thick, and it will get heavy. I have seen pictures of screens that weigh several pounds. This weight is distributed across the screen, and with a rough base, it will hold very well.
from the Algae Scrubber site
The top section of the screen, where it is inserted into the slot tube, should not be roughed up at all. This helps prevent algae from growing into the slot and blocking the flow. This is really not of major concern if you properly cut the slot, so no additional steps should be necessary. The reason is that if algae happens to grow up into the slot tube, the water pressure will increase, which will inhibit the growth of algae creeping further into the slot. A balance point is achieved.
Slot Tube Crosscuts, and others
Originally, it was recommended to place crosscuts in the slot tube. You will see this on older builds.
This is not recommended anymore, so don't do it. The idea was to allow for water to continue to flow if the algae grew up into the slot and clogged it, and also to prevent squirting. The result was that algae grew easily into the slot, because the pressure wasn't high enough to prevent it - flow was just diverted to the crosscuts. Then, the pressure was higher through the crosscuts, which resulted in squirting. The solution is the perfectly straight and correct width slot.
There have been many other attempts to 'improve' on the slotted tube design, but for one reason or another, they just don't work as well. I could list and describe them, but many of them are pictured on the Algae Scrubber site, under the sticky topic "Hundreds of new design pics are posted...".