Abstract Use of chemicals as an additive during steam-based bitumen recovery processes has been an active topic for research and development in the last four decades. In this study, thermo-physical properties of mixtures of bitumen with a newly developed chemical are reported. This new chemical technology (i.e. IPC as referred in this paper) is a proprietary mixture of surfactants that has been used in several techniques associated with surface extraction as well as in-situ recovery of heavy oil and bitumen. This formulation of solvents and surfactants is reusable, low foaming, non-flammable, not acutely toxic and non-carcinogenic. A series of tests were conducted to measure density and viscosity of a bitumen, IPC, and different mixtures of bitumen-IPC at several pressure, temperature and chemical composition conditions. It was observed that solubility of IPC in bitumen was small, and its effects on the oil phase viscosity and density could not be separated from its effects on bulk properties caused by dispersed emulsified droplets of IPC. The impact of IPC on viscosity of mixture was more pronounced than its effect on mixture density. A very complex emulsion was formed upon contact of IPC with bitumen. The results of these tests will be useful in designing a steam-based bitumen recovery process with IPC as the chemical additive. Details of thermal stability analysis of IPC are also presented. Highlights • The effects of IPC formulation on density and viscosity of bitumen-IPC mixtures were studied. • Physical properties and thermal stability of IPC formulation was studied. • IPC formulation had no significant impact on mixture density up to 100 °C. • IPC formulation decreased the mixture viscosity at 100 °C and above. • Complex emulsions were formed upon low temperature mixing of IPC and bitumen. [ABSTRACT FROM AUTHOR]