If you don't specify argument for mcrypt_create_iv(), it will use /dev/random(on Linux) by default as a random number generator. The problem of /dev/random is that it's random pool depends on the system interrupts, when there is not enough system interrupts, it cannot generate enough random numbers, then the process tries to get the random numbers will wait and hang.
So instead of
mcrypt_create_iv($size)
use
mcrypt_create_iv($size, MCRYPT_DEV_URANDOM);
See the difference then
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