A while back Drush stopped working on my servers and it would just return without doing anything. Today I decided to finally debug the issue. Turns out the FreeBSD port just fetches the Phar archive and installs it.
After digging around I found the following post which says that Suhosin blocks Phar file execution. The fix turned out to be quite simple; Just edit the Suhosin ini file (in FreeBSD it’s /usr/local/etc/php/ext-30-suhosin.ini) and add the following after the “extension” line:
suhosin.executor.include.whitelist = phar
And you’re back in business :)