fix: clean up Hermes-visible OpenClaw leftovers (#97)

* cleanup openclaw session leftovers - hermes can breathe now

* fix: load hermes adapter env from .env

* fix: redact secrets from hermes adapter error output

* addressed review findings

* address luke findings #2

src/lib/studio/settings-store.ts

@@ -6,6 +6,9 @@ import {
   defaultStudioSettings,
   mergeStudioSettings,
   normalizeStudioSettings,
+  type StudioGatewayAdapterType,
+  type StudioGatewayProfile,
+  type StudioGatewaySettings,
   type StudioSettings,
   type StudioSettingsPatch,
 } from "@/lib/studio/settings";
@@ -16,6 +19,7 @@ import {
 const SETTINGS_DIRNAME = "claw3d";
 const SETTINGS_FILENAME = "settings.json";
 const OPENCLAW_CONFIG_FILENAME = "openclaw.json";
+const DEFAULT_LOCAL_GATEWAY_PORT = 18789;
 
 export const resolveStudioSettingsPath = () =>
   path.join(resolveStateDir(), SETTINGS_DIRNAME, SETTINGS_FILENAME);
@@ -23,11 +27,21 @@ export const resolveStudioSettingsPath = () =>
 const isRecord = (value: unknown): value is Record<string, unknown> =>
   Boolean(value && typeof value === "object");
 
-const readOpenclawGatewayDefaults = (): {
+const buildGatewaySettings = (params: {
+  adapterType: StudioGatewayAdapterType;
   url: string;
-  token: string;
-  adapterType: "openclaw";
-} | null => {
+  token?: string;
+  profiles?: Partial<Record<StudioGatewayAdapterType, StudioGatewayProfile>>;
+}): StudioGatewaySettings => ({
+  url: params.url,
+  token: params.token ?? "",
+  adapterType: params.adapterType,
+  ...(params.profiles ? { profiles: params.profiles } : {}),
+});
+
+const buildLocalProfile = (url: string, token = ""): StudioGatewayProfile => ({ url, token });
+
+const readOpenclawGatewayDefaults = (): StudioGatewaySettings | null => {
   try {
     const configPath = path.join(resolveStateDir(), OPENCLAW_CONFIG_FILENAME);
     if (!fs.existsSync(configPath)) return null;
@@ -40,29 +54,110 @@ const readOpenclawGatewayDefaults = (): {
     const token = typeof auth?.token === "string" ? auth.token.trim() : "";
     const port = typeof gateway.port === "number" && Number.isFinite(gateway.port) ? gateway.port : null;
     if (!token) return null;
-    const url = port ? `ws://localhost:${port}` : "";
+    const url = port ? `ws://localhost:${port}` : `ws://localhost:${DEFAULT_LOCAL_GATEWAY_PORT}`;
     if (!url) return null;
-    return { url, token, adapterType: "openclaw" };
+    return buildGatewaySettings({
+      adapterType: "openclaw",
+      url,
+      token,
+      profiles: {
+        openclaw: buildLocalProfile(url, token),
+      },
+    });
   } catch {
     return null;
   }
 };
 
-export const loadLocalGatewayDefaults = (): {
-  url: string;
-  token: string;
-  adapterType: "openclaw";
-} | null => {
-  const fromFile = readOpenclawGatewayDefaults();
-  if (fromFile) return fromFile;
-  // Fall back to env vars so operators can configure the gateway URL at
-  // runtime without openclaw.json and without a rebuild.
-  const envUrl = process.env.CLAW3D_GATEWAY_URL?.trim();
-  const envToken = process.env.CLAW3D_GATEWAY_TOKEN?.trim();
-  if (envUrl) return { url: envUrl, token: envToken ?? "", adapterType: "openclaw" };
+const normalizeAdapterType = (value: string | undefined): StudioGatewayAdapterType | null => {
+  const normalized = value?.trim().toLowerCase();
+  if (normalized === "openclaw" || normalized === "hermes" || normalized === "demo" || normalized === "custom") {
+    return normalized;
+  }
   return null;
 };
 
+const readPortBasedGatewayProfile = (
+  adapterType: Extract<StudioGatewayAdapterType, "hermes" | "demo">,
+  envKey: "HERMES_ADAPTER_PORT" | "DEMO_ADAPTER_PORT"
+): StudioGatewayProfile | null => {
+  const rawPort = process.env[envKey]?.trim();
+  if (!rawPort) return null;
+  const port = Number.parseInt(rawPort, 10);
+  if (!Number.isFinite(port) || port <= 0) return null;
+  return buildLocalProfile(`ws://localhost:${port}`);
+};
+
+const buildEnvGatewayDefaults = (): StudioGatewaySettings | null => {
+  const envUrl = process.env.CLAW3D_GATEWAY_URL?.trim();
+  const envToken = process.env.CLAW3D_GATEWAY_TOKEN?.trim() ?? "";
+  const envAdapterType =
+    normalizeAdapterType(process.env.CLAW3D_GATEWAY_ADAPTER_TYPE) ?? "openclaw";
+
+  const hermesProfile = readPortBasedGatewayProfile("hermes", "HERMES_ADAPTER_PORT");
+  const demoProfile = readPortBasedGatewayProfile("demo", "DEMO_ADAPTER_PORT");
+
+  const profiles: Partial<Record<StudioGatewayAdapterType, StudioGatewayProfile>> = {};
+  if (hermesProfile) profiles.hermes = hermesProfile;
+  if (demoProfile) profiles.demo = demoProfile;
+
+  if (envUrl) {
+    profiles[envAdapterType] = buildLocalProfile(envUrl, envToken);
+    return buildGatewaySettings({
+      adapterType: envAdapterType,
+      url: envUrl,
+      token: envToken,
+      profiles,
+    });
+  }
+
+  const fallbackProfile = profiles.hermes ?? profiles.demo ?? null;
+  if (!fallbackProfile) return null;
+  const fallbackAdapterType = profiles.hermes ? "hermes" : "demo";
+  return buildGatewaySettings({
+    adapterType: fallbackAdapterType,
+    url: fallbackProfile.url,
+    token: fallbackProfile.token,
+    profiles,
+  });
+};
+
+const mergeGatewayProfiles = (
+  base: StudioGatewaySettings,
+  extra: StudioGatewaySettings | null
+): StudioGatewaySettings => {
+  if (!extra?.profiles) {
+    return base;
+  }
+  const mergedProfiles: Partial<Record<StudioGatewayAdapterType, StudioGatewayProfile>> = {
+    ...(base.profiles ?? {}),
+  };
+  for (const [adapterType, profile] of Object.entries(extra.profiles) as Array<
+    [StudioGatewayAdapterType, StudioGatewayProfile | undefined]
+  >) {
+    if (!profile || mergedProfiles[adapterType]) {
+      continue;
+    }
+    mergedProfiles[adapterType] = profile;
+  }
+  return {
+    ...base,
+    profiles: mergedProfiles,
+  };
+};
+
+export const loadLocalGatewayDefaults = (): StudioGatewaySettings | null => {
+  const fromFile = readOpenclawGatewayDefaults();
+  const fromEnv = buildEnvGatewayDefaults();
+  if (fromFile) {
+    return mergeGatewayProfiles(fromFile, fromEnv);
+  }
+  // Fall back to env vars so operators can configure the gateway URL at
+  // runtime without openclaw.json and without a rebuild. If no explicit
+  // URL is provided, also expose local Hermes/Demo adapter ports when set.
+  return fromEnv;
+};
+
 export const loadStudioSettings = (): StudioSettings => {
   const settingsPath = resolveStudioSettingsPath();
   if (!fs.existsSync(settingsPath)) {