I use Roadkil's Raw Copy when Acronis fails. It does a bit for bit copy, and attempts data recovery on bad sectors. If the target hard drive is bigger than the source, you'll have to use Partition Magic or something to resize the partition after it copies (or make another partition, if you want).
After Raw Copy finishes, and if the drive doesn't boot, running HDD Regenerator on it won't do anything. The bad sectors aren't on the new drive, and if they were unreadable by Raw Copy, then there's nothing there to regenerate. CheckDisk will do MUCH more for you on the new drive.