Found the solution:
https://rails.lighthouseapp.com/projects/8994/tickets/4063-rails-30-beta1-send_file-with-0-byte


On Sep 9, 6:59 pm, Andy <[email protected]> wrote:
> I'm starting to narrow down the problem.
>
> The files are being created in the "/tmp" folder.
>
> But when image.rb passes it up to simple_captcha_controller.rb, the
> files are coming through empty.
>
> The versions in "/tmp" are not empty files though.
>
> I'm using a CentOS server I configured myself (rather than a Rails
> host like EngineYard) so I'm guessing it's some sort of server
> issue.
>
> On Sep 9, 5:29 pm, Andy <[email protected]> wrote:
>
>
>
> > I'm trying to use the Rails3 Simple Captcha version from 
> > here:http://github.com/galetahub/simple-captcha
>
> > It's working 100% fine on my local environment.
>
> > In Production, I had to point the "convert" command to the correct
> > directory and then reinstall ImageMagick with the FreeType lib.
>
> > Now I'm not getting any errors in production.log but the images are
> > coming up as broken images.
>
> > Any ideas?

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