Tim:
I'm not sure I get it. You started with raw files, added 100 (roughly) dust fixes, exported to tifs and then used the PS image processor script to turn those into jpegs?
If that's what you did, the dust fixes wouldn't have anything to do with the image processor choking. Once the files are tiffs, what you did to them in LR has nothing to do with the files -- they're just zeroes and ones.
If I have this wrong, just let me know.
I HAVE seen the image processor choke before but only when I have mixed ProPhoto and sRGB files and I check "convert to sRGB" in the image processor. Could this be what heppened?
Tom