Toluene abatement has been investigated with a plasma catalytic technique without additional heating. Thin film of the Cu-Co binary oxide was coated on stainless steel mesh (SSM). The prepared Cu-Co-O/SSM was located in two annular dielectric barrier discharge (DBD) reactors. Toluene removal exhibits two-stage characteristics in the 60-mm DBD reactor. In the first stage, both full locating SSM and Cu-Co-O /SSM could equally improve the toluene removal, indicating that SSM dominates the catalytic role on toluene conversion resulting from its conductivity. In the second stage, Cu-Co-O/SSM could improve the the complete conversion of toluene, as the specific energy density is above 153 J/L by providing a reactive surface. Toluene removal exhibits one stage characteristics in the 200-mm DBD reactor. The removal efficiency and CO2 selectivity could respectively achieve 100% and 64% as the specific energy density being around 20 J/L. Partial locating SSM or Cu-Co-O/SSM could equally improve the complete toluene conversion as the specific energy density being above 8 J/L. Cu-Co-O thin film has negligible effect on toluene conversion. The gas and surface reaction mechanism has been proposed. Specific energy density and locating pattern could influence the effect of Cu-Co-O thin film coated on SSM.