NASA planners did have one fortuitous ace in the hole that made the plan possible: while
Columbia's STS-107 mission was in progress,
Atlantis was already undergoing preparation for flight as STS-114, scheduled for launch on March 1. As
Columbia thundered into orbit, the younger shuttle was staged in Orbital Processing Facility 1 (OPF-1) at the Kennedy Space Center. Its three main engines had already been installed, but it didn't yet have a payload or remote manipulator arm in its cargo bay. Two more weeks of refurbishment and prep work remained before it would be wheeled across the space center to the enormous Vehicle Assembly Building and hoisted up for attachment to an external tank and a pair of solid rocket boosters.
So an in-orbit rescue was at least
feasible—but making a shuttle ready to fly is an incredibly complicated procedure involving millions of discrete steps. In order to pull
Atlantis' launch forward, mission planners had to determine which steps if any in the procedure could be safely skipped without endangering the rescue crew.
But even before those decisions could be made, NASA had to make another assessment—how long did it have to mount a rescue? In tallying
Columbia's supplies, NASA mission planners realized that the most pressing supply issue for the astronauts wasn't running
out of something like air or water but accumulating
too much of something: carbon dioxide.
Weight is a precious commodity for spacecraft. Every gram of mass that must be boosted up into orbit must be paid for with fuel, and adding fuel adds weight that must also be paid for in more fuel (this spiral of mass-begets-fuel-begets-mass is often referred to as the
tyranny of the rocket equation). Rather than carrying up spare "air," spacecraft launch with a mostly fixed volume of internal air, which they recycle by adding back component gasses. The space shuttle carries supplies of liquid oxygen and liquid nitrogen, which are turned into gas and cycled into the cabin's air to maintain a 78 percent nitrogen/21 percent oxygen mixture, similar to Earth's atmosphere. The crew exhales carbon dioxide, though, and that carbon dioxide must be removed from the air.
To do this, the shuttle's air is filtered through canisters filled with lithium hydroxide (LiOH), which attaches to carbon dioxide molecules to form lithium carbonate crystals (Li2CO3), thus sequestering the toxic carbon dioxide. These canisters are limited-use items, each containing a certain quantity of lithium hydroxide;
Columbia was equipped with 69 of them.
How long those 69 canisters would last proved difficult to estimate, though, because there isn't a lot of hard data on how much carbon dioxide the human body can tolerate in microgravity. Standard mission operation rules dictate that the mission be aborted if CO2 levels rise above a partial pressure of 15 mmHg (about two percent of the cabin air's volume), and mission planners believed they could stretch
Columbia's LiOH canister supply to cover a total of 30 days of mission time without breaking that CO2 threshold. However, doing so would require the crew to spend 12 hours of each day doing as little as possible—sleeping, resting, and doing everything they could to keep their metabolic rates low.