To facilitate the online monitoring and control of a pilot-scale polymerisation reactor, state estimation techniques are investigated. Specifically, a batch-loop reactor is employed for the emulsion polymerisation of methyl methacrylate. The reactor consists of jacketed tubular sections fitted with in-line static mixers, thus providing mixing homogeneity and improved temperature control. A direct estimation of the reaction rate is attained through measurements of process and jacket side temperatures, and thus a calorimetric method of estimation. This is compared with a Kalman filter based calorimetric approach, in which there is compensation for model uncertainties and measurement noise. For both estimation methods, no knowledge of the kinetic model for polymerisation is needed. Experimental results indicate that with an accurate model of the process energy balance, in which, for example, the recycle pump energy input is described, the Kalman filter approach is found to provide excellent prediction of conversion, for both high and low conversions, for this pilot-plant reactor system. The approach does not require any (approximate) kinetic knowledge, and is thus considerably easier in implementation than the extended Kalman filter approaches. (C) 2004 Elsevier Ltd. All rights reserved.