Abstract Non-thermal plasma catalysis is a promising way to achieve high efficiency in applications such as energy conversion and chemical engineering. Although synergistic effects between plasmas and catalysts have been preliminarily considered as an underlying mechanism of this type of catalysis, the formation of discharges in small-size catalyst pores, which is possibly a crucial factor in plasma-activated catalysis, is still not well understood. In this paper, investigations on the interactions between a helium atmospheric pressure plasma jet (APPJ) and catalysts with micrometer-sized pores of different shapes and sizes are conducted with a 2D fluid model. Simulation results show that the existence of pores makes a subtle difference to the APPJ by changing the equivalent capacitance, indicating the potential to achieve moderate and stable APPJ-catalyst interactions. Traces of air impurities in helium can promote discharges in catalyst pores, and thus allow discharges to form in smaller pores. In the case when the catalyst channel is too small for direct APPJ penetration, we propose a method by producing a prior discharge in a relatively large cavity to supply seed electrons to ignite discharges inside the channel. The effects of channel and cavity sizes are discussed from the perspectives of discharge behavior and plasma-surface interactions. This work will contribute to the preparation of structured catalysts to potentially achieve higher efficient plasma catalysis, and better understanding of the physical processes in plasma-surface interactions inside micrometer pores.
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