Based on the additional information in the comments, see if changing the print properties to disable cover sheets would help.
But either way I wouldn't expect the same exact results with the spool output as with opening ALV in Excel directly. It just works differently, in general.
What you called download in background was downloading of a generated spool (REUSE_ALV_LIST_DISPLAY) so it also consider header, page break and the like. Interactively, you download from Grid so more options even with outdated FM. For background, look at SM37 spool attributes and/or fill parameters of the FM related to spool (TOP-OF-PAGE, IS_PRINT, etc.)
If you have the time, look for other solutions like in my answer to Read ALV Spool List more than 255 Chars and send it in Excel.
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