Some thoughts. Firstly, the image needs to be in the same projection as
your base layer. Openlayers does not reproject images on the fly. If you
instead created a layer in Geoserver from the image, then it can
reproject but you may prefer the results from doing it in proper image
transformation tools.
Assuming that you have got image in the correct projection, then make
sure you do all the calculations in that baselayer projection. Your
calculations involve a number of implicit assumptions about the
projection and looking at your code, it appears the base layer is
900913. This does not have linear scaling so I doubt it will work like
that. When you say the image represents 400x400 kilometers does that
really mean 400x400km on the ground or 400x400 projected "kms"?
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