The flames/smoke is not ACoC. That is overwhelming CoA haki use.
Zoro never used KoH or ACoC.
I have explained that before in a previous thread. Here:
This is ACoC, only black lightning.
See, no flames/smoke.
The top right scene is flames/smoke only.
That is not ACoC or KoH.
Bottom right scene is ACoC and flames/smoke.
Zoro calls that KoH. KoH is flames/smoke combined with ACoC.
With that out of the way, to answer your question. Zoro is only using 2 swords because he has had a chance to assess awakening Lucci power and he determined he only needs 2 swords to handle Lucci.
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Imagine counting flashback chapters.
I didn't know Zoro has and used KoH before he was born.
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He is. That's how he's able to block Zoro's sword. Invisible haki didn't go away. It still exist.
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What's stamina issues are you talking about.
Zoro doesn't have stamina issues with ACoC.