Dust emissions from open-pit mining pose a significant threat to environmental safety and human health. Currently, the range of dust suppressants used in coal mining is limited, often failing to account for their suitability across various stockpiles. This oversight results in poor infiltration after application, leading to insufficient crust formation and reduced durability. To explore the permeability of dust suppressant solutions in different stockpiles and develop a broader range of suppressants, numerical simulations were conducted to analyze the effects of liquid properties on infiltration rates. The results showed that increased liquid surface tension promotes infiltration, whereas higher solid-liquid contact angles and liquid viscosity inhibit it. Building on these findings, experimental work was undertaken using a water-based polyurethane with strong adhesion and low viscosity, combined with xanthan gum and polyethylene glycol, to optimize the dust suppressant formulation. The optimal binder formulation was found to contain 1.5% water-based polyurethane, 0.2% xanthan gum, and 1% polyethylene glycol. Infiltration experiments revealed distinct infiltration patterns for the dust suppressant solution in both rock and coal dust. The appropriate dosage of surfactants was also determined. The study indicated that surfactants enhance wettability and significantly reduce the solution's surface tension. For hydrophilic rock dust, moderate surfactant addition improves permeability, while excessive amounts disrupt capillary forces. In contrast, for hydrophobic coal dust, wettability governs infiltration, with surfactants enhancing this property. Based on these findings, dust suppressant solutions suitable for both rock and coal dust were formulated. The formulations demonstrated excellent permeability, consolidation effects, and water resistance, as validated by tests measuring wind erosion resistance, crust strength, and water erosion resistance.The significance of this research lies in its comprehensive exploration of dust suppressant efficacy within different particulate media and the factors influencing penetration performance, providing important guidance for industrial and environmental management. With the rapid pace of industrialization, dust generation poses a serious threat to both the environment and human health, making the development of effective dust suppressants increasingly critical. This study employs numerical simulations and experimental investigations to reveal the impact of various solution properties on penetration performance, particularly highlighting the application of a novel aqueous polyurethane binder, which demonstrates strong adhesive properties and low viscosity.Through optimization of the binder composition via orthogonal experiments, the research identifies optimal surfactant concentrations tailored for rock and coal dust, thereby enhancing the penetration and binding capabilities of the suppressants. This finding not only improves the performance of dust suppressants but also provides a scientific basis for practical applications, effectively reducing dust dispersion, improving air quality, and protecting the ecological environment.Furthermore, the study validates the effectiveness and durability of the developed suppressants through wind erosion resistance, crust strength testing, and water erosion experiments. This research offers practical solutions for the mining, construction, and related industries in controlling dust, while also providing reliable scientific support for policymakers in environmental protection. In summary, this study not only holds significant academic value but also offers actionable guidance for dust control and environmental conservation in real-world applications.