It honestly just wont work, well with the product I use "frontline" I've experimented so much with this, I'm guessing 1/4 of a drop is maximum, anymore and it kills them within 5 seconds. If you treat anywhere other than its posterior it dies too.
VV get up very early, many hours before the bees and go to bed late after the bees, as you say not nocturnal. Letting them off late isnt an option either as you need to catch so many. Not to mention all the time im treating them they are wriggling and trying to sting me with their 5mm stinger dripping with venum. Its a full time job and with feeding bees I'm shattered. Keep thinking though, I'll try anything you suggest.
I understand the handling issues that you have with stun, treat and release. If it were me I would probably adapt a small tapered butterfly net and fit a gated corral to the end of it. I would then use a small paint brush to apply the laced sugar paste. Once applied the corral is simply opened to release the hornet. That way there's no major handling issues save lifting the butterfly net by the corral so that the hornet climbs up and into the corral.
The thing is if you use a sugar paste which is wet but still viscous, you'll be able to use a stronger concentration of fipronil because the hornet will not be exposed to the full dose (contact surface area vs volume vs concentration) and what's more when the hornet gets back to the nest its colleagues will clean it thereby coming into contact with the fipronil.
As Karsal says, I'd use Fipronil ant powder in the sugar paste but you could also experiment with something like Maxforce Ant Killer Bait Gel which is ready made and paint that onto the hornet instead.