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Ok, well it looks like this is a fairly old build of Known as it's not using the imageproxy. The old way that known used to handle profile images was to fetch them and store them as a local file (to handle a security issue with webmentions), however the way it did this was a one shot deal, with no failure recovery. So, if it failed to get the file, you might get some html instead, or a zero byte file - this appears to be happening.

You could try using the latest master, since this includes the image proxy code which allows for much better recovery, and a manual retry if all else fails.