When processing abrasive ores—particularly high-silica, hard particles—polyurethane hydrocyclones deliver 3–5× longer wear life than unlined metal, maintain stable separation geometry for consistent cut size, resist corrosion across pH 2–12, and weigh dramatically less (50–80kg vs. 200–300kg for metal). However, they are temperature-limited to ≤70°C. Metal hydrocyclones (high-chromium cast iron) offer structural strength, high-temperature capability (>200°C with ceramic liners), and lower initial shell cost—but require frequent liner replacements (every 1–3 months), are vulnerable to corrosion in acidic/alkaline slurries, and have unstable separation performance as wear progresses. The optimal solution for many applications is a metal shell with polyurethane or ceramic liners—combining structural durability with wear performance.