Has this issue been resolved? Exporting the file to CSV is not a solution as when importing it to Excel all of the data types default to General. Forcing the columns columns into another format isn’t viable when there >100 columns.
Excel takes up a lot of memory, specially with large amounts of data. I have found it better to export to a text file (pipe delimited, CSV, etc.) and then have the Toad automation job call an Excel macro with a run program step. You can have the Excel macro handle opening the text file setting column formats building pivot tables, moving the data to a template, etc. Just remember to add a quit application step at the end of the macro or Toad will time out waiting for it to finish.