A process which comprised a tubular reactor (that can be packed with different internal structures) has been modeled and theoretically analyzed for conducting the hydrogenation of nitrile butadiene rubber (NBR). The dynamics of the tubular reactor and the intrinsic hydrogenation kinetics are coupled, and detailed numerical simulations are performed under isothermal and isobaric conditions. The proposed model thus obtained involves coupled, nonlinear, partial differential equations (distributed parameter system). The effect of different reactor design parameters such as Peclet number, carbon-carbon double bond loading, mass transfer to reaction resistance, and solubility of hydrogen with respect to hydrogenation of the NBR has been investigated numerically. The conversions predicted using the proposed model for tubular packed bed reactor are compared with those possible in conventional plug flow reactor and continuous stirred tank reactor models. The optimal parameters and operating conditions for efficient production of hydrogenated NBR are suggested. Finally, the validity of the proposed model is confirmed by comparing the predicted and the experimental degree of hydrogenation obtained in a tubular reactor packed with Intalox saddles. POLYM. ENG. SCI, 49:1979-1989, 2009. (C) 2009 Society of Plastics Engineers