No gooey residue. The bottom of my kettle does have a brownish color from brewing. I have to let ez clean sit in there for awhile to remove it.
I measure SRM in Beersmith.
Flameproof insulation is a great idea!
I haven't taken a temperature reading during the boil but it's a good idea.
I do 5 gallon batches. Usually I'll get .5-1 gallon boil off in an hour, so I tend to begin with 6 gallons of wort before a 60 minute boil. I've never split a batch but I should try. When you brewed this way how did you add hops? Did you split 1 ounce into 2 .5oz clumps and add one to each kettle?
A slight browning is normal as well as some from calcium oxalate (beer stone) precipitating out.
How do you "measure" SRM in BS? It calculates, but how how do you measure the SRM of your wort/beer sample? And what is your reference? A glass of beer appears a lot darker than an SRM sample size. I think judges use 1 inch in a standard tasting cup, not sure, and it's purely qualitative of course, a ballpark.
.5 gallon boil off / hour would be low. 1-1.5 gal is about normal.
When splitting the boil in say 4+2 gallons you do all your additions (salts, hops, spices) proportionally.* Your boil off tends to be higher from the smaller vessel, so keep an eye on that, or start a bit higher, like 3.8+2.2. When the boil is over, combine, chill and rack to fermentor. Or chill separately and rack. Same result.
* weight the hops, but if your scale can't resolve lower weights properly, eyeball the proportional sub-amounts, like 50/50, 40/60, etc.
The easiest is to collect and mix all wort in the main kettle, note your volume, then take out your 2.2 gallons or so for the 2nd vessel boil.
I doubt a mixer will turn the wort over and if it does, you got to watch out for HSA. Stirring will help, but is tiresome while your wort may never really "boil." I'd do the split boil. On a side note, I moved on to a 3500W induction plate, and it does the job better than the glass top stove, without fear of cracking that thing under all that weight.