Because Judge's research might be wrong, he wanted to create cold murder machines but maybe emotions make their powers stronger not weaker.
I doubt judge is that dumb
The flames might come from sora, because there's a lot of weird stuff surrounding her that needs an actual explanation
First, why is she named after a legendary warrior that defeated germa centuries ago
Second why does judge just fuck another woman? He could've had an army of genetically enhanced kids but nope, he only wants children with sora and I doubt it's because he's a good guy. He's a literally nazi
So I wouldn't be surprised if oda revealed that plot twist. She was a lunarian all along and lunarians have a unique genetic that makes them the only creatures capable of being enhanced by the experiment
That or judge is actually a great guy with honor and respect who values his wife
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That's not necessarily rivalry. Sharing a position doesn't necessarily implicate wishing to overcome the other, just saying. I mentioned for the most part it's a gag cause each time they made comments on power outputs that was displayed as a gag and never as a serious rivalry. By intuition it probably means that this rivalry is for the most part gag-ish and so not a serious business.
Besides Zoro is focused on other matters, I doubt he cares.
One piece always had gags heavily connected to the main plot
They aren't strong and close to each other's level because they are rivals, it's not Naruto and Sasuke
They are rivals because they are already close in terms of strength
So yeah they are rivals. Their strengh just isn't the result of their rivalry, it's the source of it