If you're going to run 50 sponges, and Kaldnes in the sumps, I think a
PVC manifold with air valves drilled in it would be the best option.
I tried all kinds of air-valves, and only the all-plastic ones last well with sat-water systems. Something like:
http://www.aquaticeco.com/subcategories ... stic-ValveFAF sells them at a good price too I think.
You might be able to do it with airline and valves, but it will be much more finicky getting the air all even, and not nearly as pretty/functional.
PVC is probably cheeper too, 3/4" would be fine for this kind of flow rate.
That is a pretty serious air demand, which is a good thing
IMO. It helps keep everything alive, and gets the CO2 out of the water well. Place the air-pumps outside or in a separate room to get nice clean air. CO2 can really build up in a tightly sealed fish room.
I think you're going to need at least 2 of the
sl-65 size pumps, or a larger more expensive linear pump. If it were me I'd do a small regenerative vortex blower. If you plan on growing a lot of fish having the extra air will be much appreciated in the future. They're just so reliable too.
I don't have experience with the nicer linear pumps, but the
sl-65's need work after about 2 years of service. They are cheep, but you get what you pay for. For a couple years of use, their price is really good. But for a long-term project, I'd go for something nicer.