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I think you'll be happy with a ULN-2 with +DSP. I have the 2882 2d Expanded+DSP, and I'm using its DSP mixer running effects to make cue mixes as you mention. It's nice being able to not only add reverb, but EQ the sound to make it easier on vocalists. You can even dial in some guitar amp simulation.
The only other non-digital mixer products that offer DSP based effects are the Focurite Saffire Pro 24 DSP, MOTU 828mkIII and Yamaha MR816 - none of them has the same flexibility. I like being able to forget about the DAW buffer latancy, and still offer lots of flexibility for the cue-mix.
As for headphone outs, the analog outs running at high power seems to have enough headroom to drive headphones. That's what I do, and nobody's complaining.
Hope that helps!
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