There are a couple of questions for me.
First, if this passport was one of the ones he turned in, oh, so long ago and it was revoked at that time, how come he managed to get so far as to get his boarding pass and get through the passport check to actually get on the plane? When you check in online for an international flight, you have to enter your passport number and expiry date as part of the process. There should have been some flagging there – I’m pretty certain that stuff goes to the US border authorities. Since the airline would have to bring you back on their own cost if they don’t check the validity of travel document, I am assuming there’s some real-time checking going on at that point (but I may be wrong).
(Since I have been entering and leaving the US exclusively using my passport, it’s not clear to me whether you can present a driver’s license at TSA before going through security if you are getting onto an international flight.)
If his passport was revoked basically about the time they picked him up (i.e., was valid until they came on board and said, nope, no good any more), then it will be interesting to see what triggered it.
Not being an expert in this stuff, I may be all wet, but it seems odd he could have gotten all the way onto the plane without someone catching before they came and hauled his ass away. Unless they waited for him to board the plane…