Refractory protected replaceable insert

A method of facilitating repair of a metal gasifier floor at a throat opening in the gasifier floor, the method comprising

• finishing an inner peripheral edge portion of the metal gasifier floor at a throat opening such that the inner peripheral edge portion has a first predetermined mating profile in cross-section;
• forming a replaceable floor edge insert with a radially inner edge that becomes a free edge of the metal floor at the throat opening and forming a radially outer edge having a second predetermined mating profile in cross-section that is complementary with the first predetermined mating profile of the finished inner peripheral edge portion;
• positioning the replaceable floor edge insert at the finished inner peripheral edge portion of the gasifier floor to engage the complementary first and second predetermined mating profiles of the respective finished inner peripheral edge portion and the replaceable floor edge insert such that the replaceable floor edge insert is removable from the finished inner peripheral edge portion;
• and
• prolonging the life of the metal gasifier floor at the throat opening by providing a hanging refractory brick with an appendage at the throat opening to overlie a portion of the replaceable floor edge insert, with the appendage extending into the throat opening to cover the portion of free edge of the replaceable floor edge insert and to cover a portion of an upper surface of a quench ring that underlies the metal gasifier floor at the throat opening.