Composite vane and method of manufacture

1. A vane for removing liquids entrained in a gas stream, the vane having a profile capable of formation by pultrusion, comprising:

a main curved section oriented generally parallel to the gas stream and curved to reorient the gas stream, the main curved section causing a first and a second change of direction of the gas stream;

a first air pocket formed on a first side of the main curved section, the first air pocket sized and oriented into the gas stream where the gas stream first changes direction; and

a second air pocket formed on a second side of the main curved section, the second air pocket smaller than the first air pocket and sized and oriented into the gas stream where the gas stream makes the second direction change, wherein the vane is a composite vane formed by pultrusion.

2. The vane of claim 1 , wherein the vane is formed from materials including a fiber reinforced with one or more of fiberglass, carbon, and aromatic polyamide and a thermosetting resin.

3. The vane of claim 1 , wherein a plurality of the vanes are placed at a predetermined separation to remove the liquids from the gas stream.

4. The vane of claim 3 , wherein the separation is between about 1.0 inches and about 1.8750 inches and preferably is approximately 1.625 inches.

5. The vane of claim 1 , further comprising a surface veil applied to the vanes to adjust surface wettability.

6. The vane of claim 1 , further comprising additional layers applied to the vanes, wherein the layers operate to reduce visibility to radar.

7. The vane of claim 1 , wherein the main curved section comprises a smooth curve.

8. The vane of claim 1 , wherein the main curved section comprises a series of flats approximating a smooth curve.

9. The vane of claim 1 , wherein the first air pocket, of a first composite vane in parallel construction with a second composite vane forms a first throat, wherein the gas stream is accelerated to enhance moisture entrainment by the second air pocket.

10. The vane of claim 1 , wherein the main curved section has a thickness of about 3/16 inch and the first and the second pockets are defined by pocket walls having thicknesses of about ⅛ inch.

11. The vane of claim 1 , wherein the vane has a width of about 5 inches and a length of between about 5 inches and about 144 inches.

12. The vane of claim 1 , wherein the liquid droplet removal efficiency for 30 micron droplets is 100 percent.

13. A method for manufacturing a composite vane for use in removing liquid droplets from a gas stream, comprising:

reinforcing a fiber material with one or more of fiberglass and aromatic polyamide;

impregnating the reinforced fiber material with a thermosetting resin;

pulling the impregnated reinforced fiber material through a die; and

simultaneous with the pulling step, applying heat at a constant temperature to the material, whereby the composite vane having a desired profile is formed, and whereby the desired profile comprises:

a main curved section oriented generally parallel to the gas stream and curved to reorient the gas stream, the main curved section capable of causing a first and a second change of direction of the gas stream;

a first air pocket formed on a first side of the main curved section, the first air pocket located on the composite vane where the gas stream first changes direction; and

a second air pocket formed on a second side of the main curved section, the second air pocket smaller than the first air pocket and located on the composite vane where the gas stream makes the second direction change.

14. A system for removing liquid droplets from a gas stream, comprising

a plenum housing a plurality of composite vanes, the vanes separated by a predetermined distance, each composite vane comprising:

a main curved section oriented generally parallel to the gas stream and curved to reorient the gas stream, the main curved section causing a first and a second change of direction of the gas stream,

a first air pocket formed on a first side of the main curved section, the first air pocket sized and oriented into the gas stream where the gas stream first changes direction, and

a second air pocket formed on a second side of the main curved section, the second air pocket smaller than the first air pocket and sized and oriented into the gas stream where the gas stream makes the second direction change, wherein the composite vane is formed from composite materials including a fiber reinforced with one or more of fiberglass, carbon, and aromatic polyamide, and a thermosetting resin; and

a coalescer coupled to an exit from the plenum, the coalescer comprising a filter material to further remove the liquid droplets.

15. The system of claim 14 , wherein the composite vanes comprise a series of flats having an overall generally curved shape.

16. The system of claim 14 , wherein the coalescer is combined with other coalescers or other filters and vanes.

17. A system for removal of liquids and solid particles from a gas stream, comprising:

means for changing directions of the gas stream;

means for coalescing liquid droplets from the gas stream;

means for accelerating and decelerating the gas stream; and

means for collecting the coalesced liquid droplets.

18. The system of claim 17 , wherein the means for changing directions of the gas stream comprises means for making a first and a second change of direction.

19. The system of claim 17 , wherein the means for changing directions comprises two or more composite vanes arranged in a generally parallel configuration, the composite vanes formed by pultrusion from composite materials including a fiber reinforced with one or more of fiberglass, carbon, and aromatic polyamide, and a thermosetting resin.