<p>Tetra-hybrid nanoparticles dispersed in non-Newtonian fluids have a significant impact on enhancing heat transfer, making them valuable for various industrial and technological applications. This study delves into the complex behavior of tetra-hybrid nano-fluid flow through porous disks, examining the combined effects of nanolayer chemical reactions, activation energy, and motile microorganisms. The focus is on understanding how the thermophysical properties of nanoparticles affect key parameters such as skin friction coefficient, Nusselt number, Sherwood number, and microorganism distribution. A mathematical model is formulated, and the governing equations including the 3D Navier–Stokes are transformed into nonlinear ordinary differential equations using similarity transformations. Numerical solutions are obtained through MATLAB’s code using Finite-Element Method. The study provides a comprehensive analysis, supported by detailed tables and figures that illustrate the influence of various parameters on tetra-hybrid nano-fluid flow through porous disks. Tables summarize the thermophysical properties, numerical results including Forchheimer numbers and nanoparticle volume fractions and their correlations with Nusselt number, shear stress, and heat transfer rates. Figures illustrate the impact of thermal expansion, Casson parameter, porosity, mixed convection, and magnetic field on velocity, temperature, concentration, and microorganism distribution. Key findings include trends like the decrease in stress with increasing porous-Forchheimer numbers, the impact of dimensional terms on radial velocities, and the role of Schmidt number, buoyancy ratio, and Rayleigh bio-convection on fluid dynamics in porous disks. By highlighting these factors, this research underscores potential applications in targeted drug delivery, enhanced energy conversion, and fluid dynamics control systems.</p>