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IEEE Access

Post-Quantum Cryptographic Migration for Consumer Industrial Control Systems

Anurag Bhattacharjee, Anjan Bandyopadhyay, Jay Prakash Singh, Debolina Ghosh

Published Jan 1, 2026• 0 citations
Publisher

Abstract

Consumer Industrial Control Systems (ICS) - spanning smart homes, building automation, and consumer manufacturing equipment - continue to rely on RSA and ECC-based protocols despite decade-long deployment lifecycles that extend well into the post-quantum era. The harvest-now-decrypt-later (HNDL) threat, wherein adversaries archive ciphertext today for decryption once cryptographically relevant quantum computers (CRQC) emerge, demands near-term migration for devices with 10–20-year operational horizons. We present an adaptive hybrid protocol that combines ML-KEM (NIST FIPS 203) with classical ECDH, selecting parameter sets dynamically from per-device capability profiles. Over 5,000 TLS handshakes conducted on representative consumer IoT hardware - Raspberry Pi gateways and ESP-class microcontrollers - our adaptive negotiation reduces handshake overhead by 23–31% compared with static hybrid baselines while preserving full backward compatibility with classical-only peers. We further provide a practical migration roadmap comprising a device capability taxonomy, risk-prioritised deployment guidance, and vendor-actionable cost–benefit analysis. All experimental artefacts are released as open-source to facilitate community replication

DOI
10.1109/access.2026.3747324

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IEEE Access•Jan 1, 2026•3 citations
Consumer Industrial Control Systems (ICS) - spanning smart homes, building automation, and consumer manufacturing equipment - continue to rely on RSA and ECC-based protocols despite decade-long deployment lifecycles that extend well into the post-quantum era. The harvest-now-decrypt-later (HNDL) threat, wherein adversaries archive ciphertext today for decryption once cryptographically relevant quantum computers (CRQC) emerge, demands near-term migration for devices with 10–20-year operational horizons. We present an adaptive hybrid protocol that combines ML-KEM (NIST FIPS 203) with classical ECDH, selecting parameter sets dynamically from per-device capability profiles. Over 5,000 TLS handshakes conducted on representative consumer IoT hardware - Raspberry Pi gateways and ESP-class microcontrollers - our adaptive negotiation reduces handshake overhead by 23–31% compared with static hybrid baselines while preserving full backward compatibility with classical-only peers. We further provide a practical migration roadmap comprising a device capability taxonomy, risk-prioritised deployment guidance, and vendor-actionable cost–benefit analysis. All experimental artefacts are released as open-source to facilitate community replication
Quantum computers capable of breaking RSA-2048 are projected to emerge by 2030 ± 3 years. Analysis of more than 100 primary sources indicates that 98–100% of healthcare records and 95–100% of government-classified data encrypted today are likely to face retroactive decryption under the Harvest Now, Decrypt Later (HNDL) attack model, in which adversaries collect encrypted data today and decrypt it once cryptographically relevant quantum computers become available. This paper introduces a formal time-dependent risk model that quantifies exposure as a function of data confidentiality lifetime (Ld) and attacker decryption horizon (Ha). Using the vulnerability condition Ld > Ha, we evaluate sector-specific quantum risk across healthcare, finance, government, and cloud environments, demonstrating that long-lived sensitive data faces near-certain compromise under classical public-key cryptography. The study analyzes NIST’s finalized post-quantum cryptography standards (FIPS 203–205: ML-KEM, ML-DSA, and SLH-DSA) and presents a unified five-phase migration framework addressing technical, operational, regulatory, and supply-chain constraints. Drawing on real-world deployments—including Apple iMessage PQ3, Google Chrome, Cloudflare, IBM Quantum Safe, and the U.S. Federal Government—the paper provides actionable guidance for organizations seeking to achieve 90% or greater post-quantum cryptography migration by 2030. The window for protecting long-lived data is now—not when quantum computers arrive.
The arrival of cryptographically relevant quantum computers (CRQCs) represents an existential threat to the public-key cryptographic infrastructure underpinning global enterprise operations. Enterprise security today relies on RSA and elliptic-curve cryptography (ECC) for TLS, VPNs, PKI, code signing, and identity systems—all of which are fundamentally broken by Shor's algorithm on a sufficiently powerful quantum computer. The defining risk is time-shifted compromise: adversaries can harvest encrypted traffic today and decrypt it once CRQCs exist, a threat already underway according to U.S. intelligence assessments. NIST finalized three post-quantum cryptographic (PQC) standards in August 2024 (FIPS 203/204/205) and mandates deprecation of quantum-vulnerable algorithms by 2035. Yet only 5% of organizations have implemented quantum-safe encryption and 95% lack formal quantum transition plans. This paper provides a comprehensive, threat-driven analysis across seven dimensions: quantum algorithm impact, harvest-now-decrypt-later (HNDL) threat models, enterprise asset risks (PKI, TLS, VPNs, code signing, cloud, IoT, identity, blockchain, supply chain), sector-specific vulnerabilities (financial services, healthcare, critical infrastructure), cryptographic primitive analysis, migration standards and roadmaps, and enterprise readiness gaps. The convergence of HNDL attacks already underway, multi-decade data sensitivity windows, and 12–15 year enterprise migration timelines means the migration deadline has, for most sectors, already passed.
Legacy smart HVAC controllers rely on vendor-cloud TLS secured by ECDH and RSA, both broken by Shor's algorithm, and typical 10-15 year lifespans mean today's devices remain in service through the quantum-threat era. Direct on-device post-quantum cryptography is infeasible: an ESP32-S3, representative of capable HVAC hardware, has only 339 KB free heap against the 900 KB ML-KEM-768 requires, and even classical ECDH-P256 keygen (111.93 ms) dwarfs hardware AES-128 (0.032 ms). We propose a non-invasive PQC proxy, requiring no device, firmware, or vendor-cloud changes, performing ML-KEM-768 encapsulation and ML-DSA-65 authentication (NIST FIPS 203/204) with AES-256-GCM session keys via HKDF, implemented with Open Quantum Safe liboqs on a Raspberry Pi 4B gateway. Over 500 runs, the post-quantum handshake (Steps 1-6) completes in 2.48 ms, 0.38 ms slower than classical baseline, with PQC computation around 8% of handshake time at 20 ms simulated round-trip network latency. The gateway sustains 443 sessions/second, 100% success under 32 concurrent connections, extrapolating to 3546 sessions/second on a 32-core cloud instance. Five side-channel tests, including verified in-place session-key zeroization and a fixed-vs-random TVLA timing analysis, found no exploitable timing leakage or susceptibility to man-in-the-middle attacks. The architecture is vendor-agnostic and becomes unnecessary once vendors adopt NIST PQC natively.
Abstract—The advent of fault-tolerant Cryptanalytically Relevant Quantum Computers (CRQCs) presents an existential threat to modern information security. Shor's polynomial-time quantum algorithm renders widely deployed public-key cryptographic primitives—including RSA, Diffie-Hellman (DH), and Elliptic Curve Cryptography (ECDH/ECDSA)—completely vulnerable to private key derivation. Furthermore, 'Harvest Now, Decrypt Later' (HNDL) adversarial campaigns actively intercept and store encrypted enterprise telemetry today, anticipating future quantum decryption capabilities. In response, the National Institute of Standards and Technology (NIST) finalized its primary Post-Quantum Cryptography (PQC) standards in FIPS 203 (ML-KEM), FIPS 204 (ML-DSA), and FIPS 205 (SLH-DSA). However, transitioning complex enterprise IT ecosystems to quantum-resistant primitives introduces severe architectural and computational disruptions: public key and signature sizes increase by several orders of magnitude, cryptographic handshake latencies escalate, network packets experience Maximum Transmission Unit (MTU) fragmentation, and legacy Hardware Security Modules (HSMs) lack microarchitectural support for lattice-based polynomial arithmetic. This paper provides an exhaustive, mathematically grounded technical survey and architectural roadmap for enterprise PQC migration. We formalize the Module Learning with Errors (M-LWE) and Module Short Integer Solution (M-SIS) hardness foundations, evaluate hybrid classical/post-quantum cryptographic transition models across standard transport protocols (TLS 1.3, IKEv2/IPsec, SSH), and formulate an enterprise Crypto-Agility Maturity Model. Furthermore, we construct an empirical enterprise testbed measuring throughput, connection establishment latency, memory footprints, and packet fragmentation across legacy and quantum-resistant suites. Our results show that while ML-KEM-768 achieves microsecond-level encapsulation, its 1,088-byte ciphertext expands TLS ClientHello payloads into multiple TCP segments under constrained networks. Finally, we establish open research directions in post-quantum identity federations, stateful hash signature tracking, and hardware-accelerated polynomial arithmetic. Index Terms—Post-Quantum Cryptography (PQC), FIPS 203 (ML-KEM), FIPS 204 (ML-DSA), Crypto-Agility, TLS 1.3, Lattice-Based Cryptography, Harvest Now Decrypt Later, Hardware Security Modules (HSM), Enterprise Migration.
The imminent advent of a Cryptographically Relevant Quantum Computer (CRQC) poses an existential threat to the US financial infrastructure.Current payment rails including FedWire, CHIPS, and ACH rely on RSA and ECC standards that are mathematically vulnerable to Shor's Algorithm.This facilitates "Harvest Now, Decrypt Later" (HNDL) attacks, where encrypted data is intercepted today for future decryption.This paper evaluates the migration to NIST-standardized Post-Quantum Cryptography (PQC), specifically ML-KEM and ML-DSA.We analyze the architectural challenges of integrati ng these primitives into ISO 20022 formats, focusing on the trade-offs between increased packet size and sub-millisecond latency requirements.By proposing a phased migration framework using Hybrid Cryptographic Wrappers, this research provides a roadmap for maintaining regulatory compliance under NSM-10 while preventing a systemic collapse of digital trust and the associated multitrillion-dollar risk to the US GDP.
Industrial control systems rely on long-lived cryptographic trust anchors to protect safety-critical operations, remote maintenance, and software supply chains. Quantum-capable adversaries create a time-shifted risk: encrypted traffic captured today may be decrypted later, while classical public-key signatures that authenticate devices, software updates, and forensic records may eventually become forgeable. This paper presents a secure-by-design post-quantum architecture for industrial control systems that couples cryptographic agility with the timing, availability, and safety constraints of operational technology. The architecture combines a post-quantum-ready trust fabric, hybrid and post-quantum transport profiles, gateway-anchored protection for legacy field protocols, and lifecycle governance aligned with industrial cybersecurity practice. A reproducible sizing study uses standardized artifact sizes from current post-quantum standards and representative industrial link rates to estimate bandwidth, latency, credential-storage, packetization, and maintenance-window effects. The evaluation also separates communication occupancy from control-loop timing, clarifies the certificate-chain sizing assumptions, discusses retransmission and packet-loss implications, and relates the analytical model to published embedded post-quantum benchmarking. The results show that post-quantum and hybrid handshakes are practical on Ethernet-based plant networks but become operationally expensive on low-rate telemetry links, which motivates gateway termination, session resumption, and deterministic rekeying. The resulting blueprint offers a practical migration path that reduces harvest-now-decrypt-later exposure while preserving deterministic control behavior and operational resilience.