Reproducible error when loading many reports (Load report failed - Not enough memory for operation)

Question

Environment:
Win 7 SP 1
Visual Studio Pro 2012 Update 4
Crystal Reports for Visual Studios Service Pack 10 (13.0.10.1385)
Report created in Crystal Reports XI Release 2 (11.5.8.826)
Targeting x86 .NET 4.0
Scenario:
We have a program that runs and creates a large number of reports before the process is ended. When running after many hours we'd get a Load report failed/Not enough memory of operation exception. I kept removing code and found i could reproduce just using the report.Load call. I simplified the report to a completely blank report to make sure it was nothing specific to a report I was loading. (Opened Crystal Reports XI Release 2, Save As, "Blank.rpt".). I then created, loaded, and disposed of this report in a loop. I was able to cause the same exception after 32,764 iterations on my machine. I also tried using .NET 3.5 same result. I added a counter to our main program and it also went through 32,764 report loads before the same exception was thrown. Main program uses 15 or so different reports with a variable number of subreports in each.
Sample Code to illustrate the problem:
I did this as a WinForms project since our main program is using winforms.
References added:
CrystalDecisions.CrystalReports.Engine
CrystalDecisions.ReportSource
CrystalDecisions.Shared
CrystalDecisions.Windows.Forms
using System;
using System.Windows.Forms;
using CrystalDecisions.CrystalReports.Engine;
namespace CrystalTest
    public partial class Form1 : Form
        public Form1()
            InitializeComponent();
            int i = 0;
            try
                while (true)
                    i++;
                    ReportDocument report = new ReportDocument();
                    report.Load("Blank.rpt");
                    report.Close();
                    report.Dispose();
            catch(Exception ex)
                MessageBox.Show(i.ToString() + ex.Message);
Exception:
CrystalDecisions.Shared.CrystalReportsException: Load report failed. ---> System.Runtime.InteropServices.COMException (0x80041004):
Not enough memory for operation.
   at CrystalDecisions.ReportAppServer.ClientDoc.ReportClientDocumentClass.Open(Object& DocumentPath, Int32 Options)
   at CrystalDecisions.ReportAppServer.ReportClientDocumentWrapper.Open(Object& DocumentPath, Int32 Options)
   at CrystalDecisions.ReportAppServer.ReportClientDocumentWrapper.EnsureDocumentIsOpened()
   --- End of inner exception stack trace ---
   at CrystalDecisions.ReportAppServer.ReportClientDocumentWrapper.EnsureDocumentIsOpened()
   at CrystalDecisions.CrystalReports.Engine.ReportDocument.Load(String filename, OpenReportMethod openMethod, Int16 parentJob)
   at CrystalDecisions.CrystalReports.Engine.ReportDocument.Load(String filename)
   at CrystalTest.Form1..ctor() in c:\Test Projects\CrystalTest\CrystalTest\Form1.cs:line 27

Answer 1

int = Int32. No it's not the "counter" that's causing the problem. The max size of an int32 is far far larger than 32764.
I am disposing and cleaning up the datasets in the main app. That is why I didn't include them in this test; they aren't relevant.
I'm unsure why this test program is completely irrelevant. It throws the same exception, at the same count, as the main program. It does it in substantially less lines of code than our main program. I spent days running long tests to figure out exactly what I needed to make the problem appear so I could post a clean and precise post on these forums. I then created the test program to illustrate that.
The "real" code as I said does stuff in sections and in a certain order.
For each report I need to export based on rows in a table
1. Creates a new Report Document
2. Loads the report document with the report
3. Creates a dataset of the data to display
4. Calls SetDataSource
5. Calls Report.ExportToDisk
6. Disposes DataSets
7. Closes/Disposes Reports
To help isolate the problem I first took out the export to disk part (Step 5). The problem still occurred. I then took out everything related to our data. (Step 3, Step 4, Step 6). The problem still occurred. And yes I commented out this code in our main real program. This left me with:
1. Creates a new Report Document
2. Loads the report document with the report
7. Closes/Disposes Reports
At this point i had to prove it was not dependent on the report. This makes sure it's not a database connection, or pulling too much data into the report. The most efficient test for this is a blank report.
So my order of operations becomes...
1. Creates a new Report Document
2. Loads the report document with a blank report
7. Closes/Disposes Reports
So you'll see this is exactly why I wrote this test the way that I did.
I've had a run where it error on iteration 32761. My last runs have errored on 32764. I have had many runs over many weeks that all error with the same exception.
There are no temp files left behind, With a test running you can see the temp files being added but they are immediately removed.