Transport phenomena in micropolar fluids with MHD and thermo-diffusion effects over deformable surfaces

Purpose This study aims to optimise fluid dynamics and heat transfer mechanisms in industrial applications such as metallurgical processes and polymer fabrication by examining the chemically reactive micropolar fluid flow over a stretching or shrinking sheet. The analysis incorporates key physical effects, including Hall current, Soret and Dufour effects, magnetohydrodynamics and a non-Darcy Forchheimer porous medium. Design/methodology/approach The investigation employs advanced mathematical modelling and numerical simulations to systematically analyse the governing equations. Velocity slip conditions and melting effects are integrated into energy conservation principles. Numerical solutions are obtained using MATLAB's bvp4c algorithm, enabling a detailed exploration of the influence of critical parameters such as porosity, nanoparticle concentration, velocity slip and suction on velocity profiles, thermal behaviour and concentration distributions. Findings The numerical results reveal the intricate interplay between fluid flow characteristics and thermophysical parameters. Specifically, variations in porosity, nanoparticle concentration, velocity slip and suction significantly impact velocity profiles, temperature distribution, and concentration fields. The study provides insights into optimising heat transfer efficiency and controlling fluid behaviour in industrial applications. Moreover, the magnetic field reduces fluid velocity, while the Hall current and micropolar effects enhance both flow and microrotation. Originality/value This research contributes to the field by integrating multiple complex effects–Hall current, Soret and Dufour effects, magnetohydrodynamics, and non-Darcy porous media–into a unified framework for chemically reactive micropolar fluid flow analysis. The incorporation of velocity slip and melting effects further enhances the novelty of the study, offering a comprehensive approach to improving thermal management and fluid control in industrial processes.