David A. Rockstraw, Ph. D., P. E.
Expert Witness, Chemical Engineering Consultant & Process Forensic Analyst
Welcome to the professional home of David A. Rockstraw, Ph. D., P. E., a recognized authority in chemical engineering and process analysis. With decades of experience across the chemical process industry, academia, government labs, and private practice, I provide expert guidance & testimony, and forensic analysis in areas that include chemical plant design, analysis, simulation, chemical process forensic investigation, and process safety management (though this is not an exhaustive list of my specializations).
About Dr. Rockstraw
A Distinguished Career in Chemical Engineering
Dr. David A. Rockstraw, P.E. brings extensive expertise in chemical engineering, process forensics, and intellectual property matters. As the former Robert Davis Distinguished Professor and Academic Department Head at New Mexico State University (as well as former Interim Academic Department Head of Mechanical & Aerospace Engineering and Creator/Director of the NMSBrew Brewery Engineering program) — and with over 85 expert witness engagements and 30+ technical consulting roles—I have testified in trials and arbitrations, led innovative research in the chemical process industries, and have served as co-PI and consultant on government grants through agencies such as the National Science Foundation.
Bridging Industry with Academia
My background spans commodity chemicals, specialty chemicals, petrochemicals, agricultural chemicals, fluorochemicals, pharmaceuticals and intermediates, energy, and water. I have been deeply involved in advanced topics that include:
Reaction Engineering & Kinetics
Reactor design, catalysis, fermentations, pyrophorics, and spontaneous combustion of self-heating materials.
Chemical Process Design
Process scale-up, plant & unit operation design, simulation using Aspen Plus®, DWSIM, and HYSYS®.
Process Safety & Forensics
Process safety management by 29 CFR 1910.119, runaway chemical reactions, explosions, fires, and chemical emissions by material balance calculations.
Chemical Separations
Distillation (azeotropic, extractive, batch, reactive, and other configurations), reverse osmosis, ultrafiltration, crystallization, adsorption (activated carbon), and ion-exchange.
Miscellaneous Unit Operations
Spray drying, emulsification, extrusion, and others.
Transport Phenomena
Momentum, heat, and mass transfer operations.
My technical insight extends to refinery operations, gas plants, plutonium processing, membranes and electromembrane processes, activated carbon applications, biofuels, processed foods, and advanced academic studies that include ultrasonic flash pyrolysis, nanoparticles, and additive manufacture.
Areas of Expertise
Comprehensive Technical Services
I offer a wide range of services that leverage my extensive background
Expert Witness Services
Providing testimony on chemical process design, analysis, and simulation; intellectual property, trade secret, and forensic analysis in litigation—including patent infringement, inter partes review (IPR), post-grant review (PGR), trade secret theft, and contractual disputes.
Technical Consulting
Process design, chemical process economic evaluation, construction, operation, and start-up. My expertise covers reaction engineering, kinetics, separations, and transport phenomena for both commodity and specialty chemicals.
Forensic Analysis
Utilizing material and energy balance techniques to analyze process data, determine yield losses, investigate process failures, and understand conditions leading to off-specification product and/or process incidents.
Specialized Industry Sectors
I serve clients across multiple sectors including the following.
Chemical Industries
Commodity chemicals, specialty chemicals, petrochemicals, fluorochemicals, monomers/polymers/plastics.
Pharmaceutical Intermediates & Agricultural Chemicals
Advanced process design and simulation for chemical production.
Chemical Reaction Engineering
Expertise in chemical reaction engineering, pilot plant design/operation, and process scale-up.
Process Safety Management
Ensuring compliance with 29 CFR 1910.119 and other safety standards for highly hazardous chemicals.
Tools, Techniques & Technologies
Advanced Process Simulation & Analysis
I apply state-of-the-art software and methodologies to support process evaluation and economic analysis, to evaluate the validity of processes, or to determination the causation of process design failure, including:
- Simulation Software: Aspen Plus®, DWSIM, HYSYS®, Matlab, and Mathcad for chemical plant simulation.
- Engineering Evaluations: Material and energy balances, engineering economics, and process plant economic evaluation.
Why Choose My Services?
Unparalleled Expertise in Chemical & Materials Engineering
With a proven track record across a diverse array of technical challenges—from separations and reaction engineering to safety and forensic investigations—I provide insights that help clients navigate complex chemical phenomena. My integrated approach combines deep technical knowledge with real-world application in areas such as:
Intellectual Property
Extensive expertise gained from dozens of engagements as expert witness on cases of infringement, invalidity, and trade secret theft.
Chemical Emissions
Numerous engagements to determine extent of chemical releases and emissions from a wide variety of chemical processes.
Process Safety & Hazard Mitigation
Managing risks of spontaneous combustion, runaway reactions, and explosions.
Economic & Operational Excellence
From chemical plant design to start-up and full-scale operation.
Comprehensive Forensic Analysis
Detailed evaluations of process data to identify issues related to energy balance, yield losses, product contamination, as well as IP theft.
Inquire Today
Ready to leverage expert chemical engineering consulting and forensic analysis for your project?
Inquire Today and discover how my extensive background can provide the insights and solutions you need—whether you’re addressing complex safety issues, process inefficiencies, or intellectual property challenges.