I used this very quick and dirty php code (below), modifying it for different values, and found that it works for variable lengths up to 128k. After that, for whatever reason, it doesn't work; no exception is raised, no error is reported, but the value does not show up in the subshell.
Maybe this is a php-specific limit? Maybe there are php.ini settings that might affect it? Or maybe there's a limit on the size of vars that a subshell will inherit? Maybe there are relevant kernel or shell config settings..
Anyway, by default, in CentOS, the limit for setting a var in the environment via putenv in php seems to be about 128k.
<?php
$s = 'abcdefghijklmnop';
$s2 = "";
for ($i = 0; $i < 8100; $i++) $s2 .= $s;
$result = putenv('FOO='.$s2);
print shell_exec('echo \'FOO: \'${FOO}');
print "length of s2: ".strlen($s2)."\n";
print "result = $result\n";
?>
Version info -
[root@localhost scratch]# php --version
PHP 5.2.6 (cli) (built: Dec 2 2008 16:32:08)
<..snip..>
[root@localhost scratch]# uname -a
Linux localhost.localdomain 2.6.18-128.2.1.el5 #1 SMP Tue Jul 14 06:36:37 EDT 2009 x86_64 x86_64 x86_64 GNU/Linux
[root@localhost scratch]# cat /etc/redhat-release
CentOS release 5.3 (Final)