Well the replace function http://www.w3.org/TR/xpath-functions/#func-replace takes a string and returns a string. You seem to want to create an element node, not a simple string. In that case using analyze-string http://www.w3.org/TR/xslt20/#analyze-string instead of replace could help.
Here is a sample XSLT 2.0 stylesheet:
<xsl:stylesheet
xmlns:xsl="http://www.w3.org/1999/XSL/Transform"
xmlns:xs="http://www.w3.org/2001/XMLSchema"
exclude-result-prefixes="xs"
version="2.0">
<xsl:output method="html" indent="no"/>
<xsl:template match="@* | node()">
<xsl:copy>
<xsl:apply-templates select="@*, node()"/>
</xsl:copy>
</xsl:template>
<xsl:template match="p">
<xsl:copy>
<xsl:apply-templates select="@*"/>
<xsl:apply-templates select="text()" mode="wrap">
<xsl:with-param name="words" as="xs:string+" select="('foo', 'bar')"/>
</xsl:apply-templates>
</xsl:copy>
</xsl:template>
<xsl:template match="text()" mode="wrap">
<xsl:param name="words" as="xs:string+"/>
<xsl:param name="wrapper-name" as="xs:string" select="'strong'"/>
<xsl:analyze-string select="." regex="{string-join($words, '|')}">
<xsl:matching-substring>
<xsl:element name="{$wrapper-name}">
<xsl:value-of select="."/>
</xsl:element>
</xsl:matching-substring>
<xsl:non-matching-substring>
<xsl:value-of select="."/>
</xsl:non-matching-substring>
</xsl:analyze-string>
</xsl:template>
</xsl:stylesheet>
When you run that with an XSLT 2.0 processor like Saxon 9 against the following input sample
<html>
<body>
<p>This is an example with foo and bar words.</p>
</body>
</html>
the output is as follows:
<html>
<body>
<p>This is an example with <strong>foo</strong> and <strong>bar</strong> words.</p>
</body>
</html>