Depends on how much flow you want (turns per hour) and that depends on what critters you're keeping. I run a 10g sump on my 15g sps tank and I use a dolphin pump that gives my about 300 gph for a 20xturns per hour. But I also have a closed loop on that tank.
[ October 17, 2001: Message edited by: 2poor2reef ]
A colsed loop just means that I have an external pump that pulls water from the main tank and returns it to the main tank on a closed circulation system. So I'm not looking for 100% of my water movement to come from my sump return pump. I have a low-light polyp tank that I have only 10x turnover and they do real well. I would aim for 10x as a minimum. You can supplement with powerheads inside your main tank also.
When sizing a return pump decide what turnover you want. Multiply your (main tank) water column in gallons by the hourly turnover you desire and then use a pump that will give you that turnover. Be sure to take into account the loss of throughput due to head and any plumbing elbows and the like. Also make sure that you are not restricting the output of the pump by using pipe or tubing of inadequate diameter. Those are my suggestions.
[ October 17, 2001: Message edited by: 2poor2reef ]