The significance of heat transfer during a reversible esterification process in a magnetohydrodynamic boundary layer Casson fluid flow along a vertical stretching plate is examined. The multi-slip conditions are considered in a porous medium. The presence of chemical process requiring an activation energy is considered in the analysis. The study also investigates the hydromagnetic boundary layer Casson fluid flow alongwith partial slip conditions across a vertical stretching plate. The incorporation of multi-slip constraints in a porous medium, alongside magnetic fields and other parameters, highlights its relevance in diverse engineering fields such as thermal engineering, polymerization, and biodiesel industries. Understanding the characteristics of such fluids under complex conditions is vital for optimizing heat and mass transfer in industrial applications, making this investigation timely and valuable. The nonlinear differential set of equations are solved numerically involving Runge Kutta based shooting approach of fourth order and the results are verified with the bvp4c tool and the findings are explored using graphical plots. The predominance of significant factors on flow configurations are analyzed and presented in graphs and tables. A comprehensive analysis is provided on the effects on velocity, concentration, and temperature of diverse parameters such as reaction rate constant, magnetic parameter, suction parameter, mass Grashof number, Prandtl number, Casson parameter, thermal radiation parameter and slip parameters. The tabular representation of the adverse effects of drag coefficient, rate of mass transfer and Nusselt number on flow configurations for various significant parameters is presented. It is inferred that for the case of reversible and irreversible flows, the shear stress rate escalates by 29% when the magnetic parameter elevates from 0.5 to 1.5 and about 35% when the Casson parameter elevates from 0.5 to 1.5. For the suction parameter, the coefficient of drag increased by 27% and 26% for irreversible and reversible flows respectively. When the reaction rate increases from 0.5 to 1.5, the rate of shear stress elevates by 0.5% and 0.02% for irreversible and reversible flows in order. The Nusselt number decreased about 7% and 8% when the magnetic parameter and Casson parameter rises from 0.5 to 1.5 respectively, for irreversible and reversible flows. It is noteworthy that the previous studies are in precise agreement with the present investigation.
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