Olympic DamOlympic Dam (OD) smelts copper concentratesCopper concentrate through the Direct-to-BlisterBlister process. The flowsheet was commercialized in 1989 however the currentCurrent plant has been in operationOperation since 1999 and consists of a feed preparation plant (FP), flash furnaceFlash furnace (FF), acid plantAcid plant (AP), electric slag cleaning furnaceSlag Cleaning Furnace (EF) and two anode furnacesAnode furnace (AF). Developments over the last 25 years has primarily been focused on improving the maintainabilityMaintainability and operability of the plant with the goal of safely and sustainably increasing furnaceFurnace campaign life. The operationOperation has targeted designDesign improvements in historically difficult to maintain areas, i.e. furnaceFurnace internal refractoriesRefractories. With the target of either minimizing the impact of the process on the furnaceFurnace or increasing the amount of maintenance that can be safely executed between furnaceFurnace campaigns. The staged rollout of Composite FurnaceFurnace Module (CFM) type cooling elementsCooling elements in high wear regions of the furnaceFurnace has significantly decreased the wear rate of refractoriesRefractories within the furnaceFurnace [5]. Improved monitoring of sidewall refractoryRefractories condition through imbedded thermocouples in the refractoriesRefractories has increased the operationsOperation understanding of factors that influence freeze liningFreeze lining stability. Installation of additional burners and improved management of furnaceFurnace binding springs during furnaceFurnace downtime has resulted in the ability to maintain negligible hearthHearth growth. Improved designDesign, operationOperation and monitoring of the OD flash furnaceFlash furnace has allowed the safe and sustainable extension of campaign life from 3 to 6 years.