Safety of old, unopened bottles of ketchup

I don't have a recipe, but if you had say a dehydrator, ketchup, and whatsit--dextrose?--that helps dry things resist clumping, you could make your own. I believe Ferran Adria carries a powder product, on his website albertyferranadria.com.

Add the powder to your own tortilla chips that you've just fried, and should work.

Alternatively, multiplex movie theatres often have several different shakers of flavourings--cheese, sour cream/onion, that sort of thing. Perhaps Costco would carry something similar.

Anything can spoil eventually, refrigerated or not. Keeping something under a lid and refrigerated restricts the number of airborne colonizers that might get access to it, and the cold temperature means that even if they get there, they will grow much slower than at room temperature.

For something to spoil, it needs to be colonized by bacteria or fungus spores, and it needs to contain some nourishment to support their growth, not too much chemicals that prevent their growth, and not too much competing life forms already present. So, things with a high concentration of salt or sugar tend to be unhospitable to bacteria and fungi growth, because they are hygroscopic (they draw the water out of cells). Extreme high or low pH (eg acidic) also retards growth. Think of things like ketchup, mustard, jelly with labels that say "refrigerate after opening" but most people ignore them. Alcohol is unfriendly if the concentration is too high, and of course natural fermented foods are already occupied by human-friendly bacteria.

Ketchup is sealed in a bottle, usually with no fingers or utensils inserted into it, so it stays pretty sterile. It is also protected by being hygroscopic (due to high concentration of sugar and salt) and its acidity. Ketchup as a word and concept is descended from an Indonesian fish sauce, and has been around much longer than refrigeration. I think you can leave it out with no worries unless you see obvious mold growth.