Fluid flow, conjugate heat transfer and different operating parameters for a blister copper flash furnace tap hole assembly were evaluated using the multi-physics capability of STAR-CCM+ Version 5.02.009 as part of Bateman Engineering Projects ongoing development program to design and manufacture robust pyrometallurgical process furnace containment equipment capable of increasing campaign lives between partial and complete rebuilds. Furnace containment equipment is frequently used in conjunction with DC open arc, open bath smelting and lower side wall refractory cooling systems applications. The equipment is capable of resisting chemically aggressive slag combined with erosion and high convective heat transfer from bath movement and has been commercialised and refined, based on Composite Furnace Module (CFM) technology originally developed and patented by the University of Melbourne. Bateman has adapted CFM technology further for application in Flash Furnace containment processes that is susceptible to copper sulphur acid attack. A multi-physics approach is developed to predict the transient heat transfer in the tap holes of blister tapping and plugged clay conditions for prescribed durations. Conjugate heat transfer loads are derived directly from the blister fluid flow regime for the composite tap hole assembly that includes both the blister bath hot face boundary and copper panel water-cooling components. Field temperature measurements were used to numerically predict the required external oxygen fuel burner heat flux required to obtain similar temperatures at selected points within the model. This data was subsequently used to compare different tap hole inserts and a new prototype tap hole assembly before manufacturing and possible installation during a planned shutdown of a flash furnace at the end of November 2010. This presentation demonstrates the approach followed in more detail, and presents predicted CFD results of the current tap hole performance which was used as a benchmark for comparison with the CFD results obtained for a new prototype tap hole assembly. Shown below is a selection of predicted CFD results obtained with STAR-CCM+ that will also be shown in the presentation.