Services – Expert Chemical Engineering Consulting & Forensic Analysis
Dr. David A. Rockstraw, Ph.D., P.E. offers a comprehensive suite of services that bridge the gap between advanced chemical engineering and real-world process challenges. With decades of experience in academic, industrial, and government laboratory settings, his services are designed to address complex technical issues in areas including commodity chemicals, energy, water, petrochemicals, pharmaceuticals, agricultural chemicals, fluorochemicals, monomers, polymers, plastics, and more; as well as provide litigation support as a testifying expert who is also capable of performing and directing laboratory investigations leading to statistically-significant data.
Expert Witness Services
Litigation & Intellectual Property Support
Rockstraw has testified in deposition, trial, arbitration, inter partes review (IPR), and post grant review (PGR). He has appeared in United States Federal Court, the International Trade Commission, before the European Patent Office (Germany), the Vienna International Arbitral Centre (Austria), and had testimony entered before the International Court of Arbitration of the International Chamber of Commerce (France), the Superior Court of Justice (Canada). He has sat in the witness chair for 20 hours in a single trial.
Rockstraw has strong laboratory and pilot plant skills, can design and build chemical process experiments at both scales, and is able to design and carry out experiments to collect statistically-significant data. Rockstraw has rented lab space at a major academic institution on the east coast, relocated temporarily to the region, then spent a month performing chemical reaction engineering research in support of a patent infringement litigation.
Rockstraw is highly skilled at use of material and energy balance concepts to provide forensic analysis of process data to account for yield losses, product contaminations, or understand conditions leading to process failures, explosions, or fires. Valuable in cases involving contractual disputes over use of natural resources, utilization of raw materials, or source of product contamination. In one matter, Rockstraw was able to extract evidence of technology theft from over four years of DCS process data of a chemical process facility (nearly 1/4 of a billion data points).
With over 85 expert witness engagements and extensive deposition and trial experience, his testimony is trusted in high-stakes litigation and arbitration.


Technical Consulting Services
Process Design & Economic Evaluation
Leverage advanced technical consulting for your chemical process needs, including:
- Chemical Plant Design & Simulation: Utilizing industry-standard tools such as Aspen Plus®, DWSIM, HYSYS®, Matlab, and Mathcad to optimize plant performance.
- Economic Evaluation & Engineering Economics: Detailed analysis of capital and operating costs, cash flow, and overall project viability.
- Plant Construction, Operation & Start-Up: Guidance through every phase—from initial design to successful operational launch.
Dr. Rockstraw’s expertise spans a wide array of chemical process sectors, including commodity chemicals; energy; water; petrochemicals; pharmaceuticals; agricultural chemicals; fluorochemicals; monomers, polymers and plastics; plutonium processing; membrane/electromembrane processes; safety; biofuels; processed foods; and academic administration. His expertise in reaction engineering, kinetics, transport phenomena, process scale-up, catalysis, heat and mass transfer ensures your process is both efficient and safe.
Forensic Analysis Services
Uncovering Process Anomalies & Failures
When process failures occur, Dr. Rockstraw’s forensic analysis is your key to understanding what went wrong:
- Material & Energy Balances: Detailed investigations to account for yield losses, product contaminations, and inefficiencies.
- Process Data Analysis: Utilizing extensive datasets—from activated carbon applications to ultrasonic flash pyrolysis—to pinpoint the causes of process anomalies.
- Safety Investigations: Evaluating conditions leading to spontaneous combustion, runaway reactions, explosions, and BLEVE incidents.
In one matter, Rockstraw was able to extract evidence of technology theft from over four years of DCS process data of a chemical process facility (nearly 1/4 of a billion data points).
His forensic services are invaluable in cases involving processed foods, reverse osmosis, ultrafiltration, spray drying, emulsification, extrusion, fermentation, distillation, azeotropic distillation, and more.


Additional Technical Expertise
Broad Industry & Technical Knowledge
Dr. Rockstraw’s technical expertise covers a wide spectrum of chemical engineering topics:
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.
Chemical Separations
Distillation (azeotropic, extractive, batch, reactive, and other configurations), reverse osmosis, ultrafiltration, crystallization, adsorption (activated carbon), and ion-exchange.
Transport Phenomena
Momentum, heat, and mass transfer operations.
Advanced Materials & Processes
Nanoparticles, additive manufacture, fluorochemicals, and sulfonylureas.
Ready to Optimize Your Process or Resolve a Technical Dispute?
Contact Dr. Rockstraw Today to discuss how his expertise can help you achieve your project goals or resolve complex technical issues.