What are the VLANs used for?
What do you mean by gateways on VLANs? Are you talking about the firewall itself having an IP address on each VLAN's subnet? Of course you need that if the firewall is to act as a router. Or are you talking about some upstream gateway? What would that be for?
What do you mean by "VLAN separation"? VLANs do separation by nature. Maybe it'd be more clear if you describe what the VLANs are for.
What do you mean by "VLAN binding", and how would you "use up" LAN interfaces with them?
You mention "collapsing a bunch of the /24 networks" - what are those used for (why do they exist)?
Note that the ports in your new Protectli box are not switch ports - they are individual NICs. You could do software bridging across them, but it's not very efficient.The usual configuration would be one physical LAN port, connected to a physical switch, with whatever VLANs you need, tagged.
I still don't really understand your second question. VLANs don't "use up" physical interfaces, unless you mean in the context of my second paragraph above (re. mixing untagged and tagged bridges).
“Use up” is again my lack of proper understanding of terminology. The VLANs (in the prior thinking) would be associated to bridges, and the bridges would be associated to physical interfaces.
I would connect the OPNsense with a redundant (LAGG) link to one of the existing switches with all VLANs on top of that LAGG interface, then connect the other switches to that first switch or in a daisy chain.
With a single trunk, LAGG or single interface, into OPNsense you can have as many VLANs as you practically want and have OPNsense route and filter between them. The switches need only be layer 2, of course in that case. Just carry the VLANs via trunks from switch to switch.