I have done remedial engineering for a number of years on large commercial buildings and have run into lots of design errors in my day. Cooling airflow issues always stand out as particular problems, but heating water issues rarely come up unless you are having a problem making capacity. Assuming that the house has an adequate system already installed and you are only able to move half the design flow of the boiler, the temperature difference will be double, but the heat will still get through to the end of the pipe. A 40 degree delta isn't efficient, but neither is an oversized pump that erodes your fittings whenever the system is in operation.
A storage tank would be my first suggestion, but having an oversized multispeed pump should allow you to slow it down in mild weather and keep the erosion manageable. I would also suggest a Spirovent in the system to catch any "microbubbles". Since you seem to be pushing the limits of what a residential circulator can do, it might be time to look at a commercial circulator. These can be had with a 3 phase motor that can be run off a speed drive for infinitely variable flow and maintain excellent energy efficiency at reduced speeds. It isn't a cheap option, but might solve most of the problem.
Chris
A storage tank would be my first suggestion, but having an oversized multispeed pump should allow you to slow it down in mild weather and keep the erosion manageable. I would also suggest a Spirovent in the system to catch any "microbubbles". Since you seem to be pushing the limits of what a residential circulator can do, it might be time to look at a commercial circulator. These can be had with a 3 phase motor that can be run off a speed drive for infinitely variable flow and maintain excellent energy efficiency at reduced speeds. It isn't a cheap option, but might solve most of the problem.
Chris