Are you not able to take PPI's, or are you getting these symptoms even on them? Did the Carafate suspension seem to work better? If you've read any of my posts, you'll know I'm a big proponent of Carafate suspension, and find it helps my reactive stomach tremendously. Since my wrap is created out of my stomach, it also becomes easily irritated, and the Carafate coating really makes it feel better. I've never heard of Carafate as a solution to acid reflux, but I know it's the drug of choice for bile reflux. It was originally developed to protect the stomach lining while ulcers healed.
Carafate and Gaviscon are very different. Carafate has no antacid properties. It's meant to coat your stomach period. The suspension does do a good job of coating the esophagus as well, and the advantage is that it lasts up to 6 hours, where Gaviscon and Maalox products are much shorter-acting.
I've taken Carafate tablets in the way your doctor suggested, and while they work some, it's not at all as good as the suspension, which coats evenly.
What you're describing almost sounds like a reaction to the drug. Could you be sensitive to it? Perhaps the more you used it, the more it irritated the throat tissue?
As far as sleeping goes, raising the head of your bed 7 or 8 inches by putting something under the legs is far superior to a wedge. The wedge allows you to slide down, and actually puts your stomach in a position that promotes reflux, because you're kind of bent in the middle.
While some seem to find it unpleasant to sleep on a "hill" like that, it's something that can be adjusted to with time, and it is very beneficial.
Refrain from eating 4 hours before bedtime to be safe.
Have you tried a liquid Gaviscon or Maalox product? You might find it even more soothing than the tablet form.
I hope you find a solution to your problems.