Metal carbonyls are used in a number of industrially important carbonylation reactions. In the oxo process, an alkene, hydrogen gas, and carbon monoxide react together with a catalyst (such as dicobalt octacarbonyl) to give aldehydes. Illustrative is the production of butyraldehyde from propylene:
:CHCH=CH + H + CO → CHCHCHCHO
Butyraldehyde is converted on an industrial scale to 2-ethylhexanol, a precursor to PVC plasticizers, by aldol condensation, followed by hydrogenation of the resulting hydroxyaldehyde. The "oxo aldehydes" resulting from hydroformylation are used for large-scale synthesis of fatty alcohols, which are precursors to detergents. The hydroformylation is a reaction with high atom economy, especially if the reaction proceeds with high regioselectivity.
Another important reaction catalyzed by metal carbonyls is the hydrocarboxylation. The example below is for the synthesis of acrylic acid and acrylic acid esters:
Also the cyclization of acetylene to cyclooctatetraene uses metal carbonyl catalysts:
In the Monsanto and Cativa processes, acetic acid is produced from methanol, carbon monoxide, and water using hydrogen iodide as well as rhodium and iridium carbonyl catalysts, respectively. Related carbonylation reactions afford acetic anhydride.