I have been using Rotella 15W-40 as well for over the past 6 yrs now. I did a 3000 miles round trip from Los Angeles to Montana and i burned about a quart in doing so.
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A catch can is on my list, possibly the one from Epic Cruisers when they're back in stock. Where'd you get yours or did you build it yourself?I think the oil consumption on any of our LandCruisers is a combination of Valve Stem Seals, PCV and blowby past the rings due to high RPM operation or under heavy load, or both.
Personally, I'm a bit surprised at the oil catch can which needs to be dumped every fill up, as it always contains a few fluid ounces of engine oil which otherwise would have been ingested by the engine via the intake, or coated the inside of the intake manifold requiring cleaning at some point.