How about this? Take the old Blowfish block encryption algorithm and eliminate the key expansion and expand it so that the s-boxes and p-array take up 16TB of d

How about this? Take the old Blowfish block encryption algorithm and eliminate the key expansion and expand it so that the s-boxes and p-array take up 16TB of data? What you'd wind up with is a block cipher that has a 16TB key. Since Blowfish is clearly "prior art," and is unencumbered by patents, this might make this approach harder to attack using patent law.