Surprisingly, Zoro actually says sanji by his name. The first was episode 45 just after nami joined the crew. Second, was during the Foxy arc (only in the manga) When Zoro and Sanji had to team up. Lastly, was the skypica arc (anime only) when the party was going on and Sanji asked/forced Zoro to help him cook
Sanji Call Zoro by His Name in epsisode 57
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