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if the area given is 100 square inches you can use 10" by 10" duct due to a black art known as aerodynamics or compressible fluid flow, you will get the same back pressure in a 10" diameter round duct and a 2" x 50" duct considerably more back pressure a nice manufactured 90 will take as much back pressure as 50' of duct a tight curved 90 will take as much as 100 feet of duct fans have a curve that goes from maximum cfm at no pressure to minimum cfm at max pressure the fan will require the most power when cfm * pressure is highest simple as rocket science i guess
Air return duct and filter grille size is dictated by the size of the unit (CFM) not the size of the house.
You need 350 to 400 cfm per ton (12,000 btu) of cooling. So, divide your cfm by 400. For example, a 1200 cfm blower on an air handler could handler up to 3 tons. All calculations depend on your duct being the proper size for the equipment.
There are 400 cfm in 1 ton