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This study aimed to optimize the ventilation system and reduce dust mass concentrations by combining numerical simulations with response surface methodology (RSM). A simplified geometric model was developed in SpaceClaim, and numerical simulations were performed using ANSYS Fluent. Single-factor analysis and a Box--Behnken experimental design were employed to investigate the effects of the exhaust duct inlet angle, exhaust-to-forcing airflow ratio, exhaust duct inlet diameter, and forcing duct outlet diameter. The results showed that the exhaust duct inlet angle and diameter were the dominant factors affecting dust distribution. Through multi-objective optimization, the dust mass concentrations at the lower and upper return-air-side corners were reduced by 58% and 34%, respectively. Validation using a 1:4 scaled-model experimental platform showed that the experimental measurements agreed well with the numerical predictions, with relative errors below 5%. This study developed an integrated research framework combining numerical simulation, response surface optimization, and scaled-model experimental validation to address dust accumulation in the return-air-side corner regions under a long-forcing, short-exhaust hybrid ventilation system. The proposed framework enables the coupled analysis of multiple ventilation parameters and the dual-objective optimization of dust mass concentrations at the upper and lower return-air-side corners, providing a reference for dust control and ventilation parameter optimization under similar operating conditions.<\/jats:p>","DOI":"10.1371\/journal.pone.0338763","type":"journal-article","created":{"date-parts":[[2026,9,23]],"date-time":"2026-09-23T17:26:06Z","timestamp":1790184366000},"page":"e0338763","update-policy":"https:\/\/doi.org\/10.1371\/journal.pone.corrections_policy","source":"Crossref","is-referenced-by-count":0,"title":["Research on dust control and ventilation parameter optimization in roadhead mining based on response surface methodology"],"prefix":"10.1371","volume":"21","author":[{"given":"Xiaokun","family":"Zhao","sequence":"first","affiliation":[{"name":"Shanxi Datong University","place":["Datong, Shanxi, China"],"department":["School of Coal Engineering"]},{"name":"Shanxi Datong University","place":["Datong, Shanxi, China"],"department":["The Cultivation Base of Shanxi Key Laboratory of Coal Mine Water Jet Technology and Equipment"]}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0009-0009-9962-5230","authenticated-orcid":true,"given":"Yuting","family":"Zhang","sequence":"additional","affiliation":[{"name":"Shanxi Datong University","place":["Datong, Shanxi, China"],"department":["School of Coal Engineering"]},{"name":"Shanxi Datong University","place":["Datong, Shanxi, China"],"department":["The Cultivation Base of Shanxi Key Laboratory of Coal Mine Water Jet Technology and Equipment"]}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Jun","family":"Ge","sequence":"additional","affiliation":[{"name":"Shanxi Datong University","place":["Datong, Shanxi, China"],"department":["School of Coal Engineering"]},{"name":"Shanxi Datong University","place":["Datong, Shanxi, China"],"department":["The Cultivation Base of Shanxi Key Laboratory of Coal Mine Water Jet Technology and Equipment"]}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Wencai","family":"Wang","sequence":"additional","affiliation":[{"name":"Inner Mongolia University of Science and Technology","place":["Baotou, Inner Mongolia, China"],"department":["School of Mining and Coal"]}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Yuhua","family":"Bai","sequence":"additional","affiliation":[{"name":"Shanxi Datong University","place":["Datong, Shanxi, China"],"department":["School of Coal Engineering"]}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Donghui","family":"Yang","sequence":"additional","affiliation":[{"name":"Shanxi Datong University","place":["Datong, Shanxi, China"],"department":["School of Coal Engineering"]},{"name":"Shanxi Datong University","place":["Datong, Shanxi, China"],"department":["The Cultivation Base of Shanxi Key Laboratory of Coal Mine Water Jet Technology and Equipment"]}],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"340","published-online":{"date-parts":[[2026,9,23]]},"reference":[{"issue":"10","key":"pone.0338763.ref001","doi-asserted-by":"crossref","first-page":"1311","DOI":"10.3390\/min13101311","article-title":"From dust to disease: A review of respirable coal mine dust lung deposition and advances in CFD modeling","author":"E Madureira","year":"2023","journal-title":"Minerals"},{"issue":"3","key":"pone.0338763.ref002","doi-asserted-by":"crossref","first-page":"433","DOI":"10.3390\/min13030433","article-title":"A toxicological study of the respirable coal mine dust: Assessment of different dust sources within the same mine","author":"M Das","year":"2023","journal-title":"Minerals"},{"issue":"2","key":"pone.0338763.ref003","first-page":"123","article-title":"Simulation optimization model and experimental verification of double cathode electrostatic precipitator","author":"Y Liu","year":"2024","journal-title":"Sintering and Pelletizing"},{"issue":"1","key":"pone.0338763.ref004","first-page":"104","article-title":"Research into dust control technology of single lane long quick tunneling ventilation system. 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