A hierarchical extended Kalman filter (EKF) design is proposed to estimate unmeasured state variables and key kinetic parameters in a first principles model of a continuous ethylene-propylene-diene polymer (EPDM) reactor. The estimator design is based on decomposing the dynamic model into two subsystems by exploiting the triangular model structure and the different sampling frequencies of on-line and laboratory measurements directly related to the state variables of each subsystem. The state variables of the first subsystem are reactant concentrations and zeroth-order moments of the molecular weight distribution (MWD). Unmeasured state variables and four kinetic parameters systematically chosen to reduce bias are estimated from frequent and undelayed on-line measurements of the ethylene, propylene, diene and total polymer concentrations. The state variables of the second subsystem are first-order moments of the MWD. Given state and parameters estimates from the first subsystem EKF, the first-order moments and three non-stationary parameters added to the model for bias reduction are estimated from infrequent and delayed laboratory measurements of the ethylene and diene contents and number average molecular weight of the polymer. Simulation tests show that the hierarchical EKF generates satisfactory estimates even in the presence of measurement noise and plant/model mismatch. (C) 2004 Elsevier Ltd. All rights reserved.