Is it permissible for a financially capable woman to pay the Zakat to her sons or one of them?
It is permissible for a mother to give her children from zakat if they are eligible to receive it, even though she is obligated to provide for them. This is based on the saying of the Prophet Muhammad (PBUH) regarding Zainab, the wife of Abdullah Ibn Mas'ud (may Allah be pleased with them): "Your husband and your children are more deserving of your charity" [Al-Bukhari]. And Allah Knows Best.
My brother is settling a debt on my behalf and in return he takes 30% interest as an additional amount of the whole sum. Is this lawful or not?
This additional amount is considered prohibited interest (Riba) according to Islamic law, and it is not permissible to take it. And Allah Knows Best.
What should a sick person, who is incapable of fasting, and who didn`t make up for missed fasting days, do?
One who has missed fasting days is obliged to make up for them, but if he/she wasn`t able to because of an incurable disease , or old age, then he/she has to pay a ransom which is feeding a needy person for each of the missed fasting days. And Allah Knows Best.
Is Zakah due on the orphan`s money?
Yes, Zakah is due on the money of the orphan.