ABSTRACT This article investigates the effect of activation energy on Carreau fluid flow in the presence of variable thermal conductivity, inclined magnetic field, melting heat transfer, and Soret and Dufour phenomena. A set of suitable similarity transformations is applied for transforming the governing partial differential equations (PDEs) considered for the physical phenomena into non-linear ordinary differential equations (ODEs). We obtained the results by solving the non-linear ODEs numerically which describe the behavior of the velocity, temperature, and concentration profiles of the fluid against the governing parameters and illustrated these graphically. The velocity distribution decreases for angle of inclination while it is increasing against higher melting parameter. The temperature distribution enhances with higher modified Dufour parameter and Prandtl number while it declines for thermal conductivity, activation energy, and melting parameters. The concentration distribution increases for melting parameter, Soret number, and activation energy parameter while decreasing for temperature difference parameter, Schmidt number, and reaction rate parameter. Skin friction, Nusselt and Sherwood numbers are evaluated numerically against the various governing parameters. Accuracy of the present work is illustrated and established through comparison carried out for skin friction versus magnetic parameter with existing results in the literature.