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Energy | Customer Stories

Securing Data Flow for a Fortune 500 Petrochemical Company with MetaDefender Optical Diode (Fend)

How a North American Fuel Provider Secures Conditional DCS Data with Fend Data Diodes
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About the Organization: A Fortune 500 petrochemical company operates 20 refineries across North America, producing essential fuels, lubricants, and petrochemicals used globally. With thousands of employees, the company’s operations rely on DCS (distributed control systems) that continuously generate and transmit critical process data. Maintaining secure and reliable data flow is essential for both regulatory compliance and safe operational performance.

What's the Story? For years, the company relied on firewalls to control outbound data flow from its OT network to its enterprise IT systems. These firewalls enabled conditional data transfer for monitoring and compliance but required continuous updates and maintenance, leaving them vulnerable to threats in between patches and configuration changes. When the firewall manufacturer announced EOL (end-of-life) support by 2025, the company had to make a change and saw the opportunity to both enhance and simplify their industrial cybersecurity protections.

Due to the nature of the business, the name of the organization featured in this story has been kept anonymous in order to protect the integrity of their work.

INDUSTRY:

Petrochemical

LOCATION:

North America

SIZE:

Thousands of Employees

PRODUCTS USED:

OPSWAT MetaDefender Optical Diode (Fend)

End-of-Life and End-of-Protection

When the point solutions organizations rely heavily upon become obsolete (or in this case are discontinued) they can face immediate and often severe risks to their flow of business. Without critical patches, cybersecurity solutions cannot stay ahead of new and emerging threats—and that leaves the organization using them vulnerable. When this North American petrochemical company needed to replace their existing firewall solution, they knew that moving quickly was essential.  

With their firewalls reaching EOL, this put the air gap between IT and OT environments at immediate risk, leaving the organization with critical vulnerabilities to consider. 

  • Loss of Security Controls – Without a replacement, refineries risked unauthorized access to critical OT data. 
  • Operational Disruptions – A lack of secure data transfer would slow down decision-making, affecting production and compliance reporting. 
  • Increased Cyber Risk – Firewalls require frequent patching to plug vulnerabilities; failing to maintain updates could expose refinery networks to ransomware, zero-day exploits, and remote access attacks. 
  • Financial Impact – Downtime caused by an insecure or ineffective replacement solution could result in millions of dollars in lost revenue. 
Diagram illustrating risks to securing data flow when firewalls reach end-of-life in refinery OT networks
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With our air gap potentially left vulnerable we knew we had to move quickly, but not at risk of choosing a replacement solution that wasn’t the right fit for us.

Out with Firewall, In with Diode 

After evaluating multiple options, the company selected OPSWAT’s MetaDefender Optical Diodes (Fend XE15) to replace the EOL firewalls. Unlike firewalls, which rely on software rules and require updates, data diodes enforce security at the hardware level, allowing only one-way data flow and preventing any potential inbound threats from reaching refinery control systems. A significant upgrade over a firewall alone, the Fend diode came with additional benefits outside of the hardware-enforced data flow. 

  • Seamless Integration – The Fend XE15 diodes were designed to directly replace firewalls with minimal reconfiguration. 
  • Zero Maintenance Security – By eliminating software-based protections, the diodes removed the need for constant patching. 
  • Scalability – The diodes are compact, rugged, and cost-effective enough to be deployed across all refinery locations. 
Diagram visualizing hardware-enforced one-way data flow with MetaDefender Optical Diode in refinery environments
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The peace of mind knowing that we have the uncompromising security of a data diode protecting our OT network from threats allows us to focus on our business and frees up resources.

Key Results

Regulatory Compliance

Secure, one-way data transfer ensures that refinery process data is accurately reported for safety and environmental regulations.

Stronger Cyber Resilience

Eliminating attack vectors associated with bidirectional communication reduces exposure to APTs (advanced persistent threats), malware, and insider threats.

Operational Efficiency

Uninterrupted data transfer allows real-time monitoring of refinery performance, preventing costly production

Long-Term Stability

The company no longer worries about discontinuation or future patching requirements.

Securing Today’s Critical Environments from Tomorrow’s Threats 

With MetaDefender Fend data diodes now in place, the company has secured its refinery operations against cyberthreats while reducing long-term security and maintenance costs. This data transfer strategy ensures continued compliance, uptime, and business continuity for decades to come. 

Are you ready to put MetaDefender Optical Diode between your essential environments and the advanced attacks that threaten them? Talk to an expert today to learn why OPSWAT is trusted globally to defend what’s critical.  

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