In a greenfield MBBR design, you start with the calculation of the media requirement, and then proceed to size the tank. The volume of media required is a function of BOD and NH3 loading, the protected surface area of the media, and the surface area loading rate (SALR) for that specific media. SALR varies widely for different types of media (for example SALR for chip media is low, compared to SALR for a conventional, pinwheel type). You can fill up to 66% so if CAPEX is your main concern, you can design like that, but it's risky, because it doesn't leave much room for error or expansion. You should also consider multiple stages, rather than a single larger tank, and your % fill may be different from stage to stage.