• By combining NH4Cl roasting with ammonia leaching process, s-LMO achieved closed-loop recovery.
• Overall Li recovery rate exceeded 96%, achieving 99% selective precipitation of Mn.
• No impurity cations were introduced in the whole process.
• Battery-grade Li2CO3 and Mn3O4 recovered were used to regenerate LMO.
• The regenerated LMO exhibited great electrochemical performances.
With the impending surge in retired lithium-ion batteries, developing efficient strategies for recovering valuable elements has attracted significant attention. This study presents an innovative closed-loop recycling method that integrates NH4Cl reductive roasting with a selective ammonia leaching system to achieve the complete recovery and regeneration of lithium and manganese from spent LiMn2O4 cathodes. The reaction mechanism was elucidated using XRD, SEM-EDS, and XPS demonstrating that Mn4+/Mn3+ in the LiMn2O4 spinel structure is simultaneously reduced and chlorinated by NH4+ from molten ammonium salts. This synergistic process efficiently converts the cathode material into water-soluble LiCl and (NH4)2MnCl4. Notably, residual nitrogen is stored and recycled as NH4+, with no impurity cations introduced during roasting. Under optimized roasting conditions (350 °C, 15 min, w(s-LMO)/w(NH4Cl) = 1:2.5), the chlorination extent of manganese reached 88%, with the residual fraction stabilized as Mn3O4, while the lithium conversion efficiency approached 96%. Subsequent leaching in an NH3·H2O–H2O system enabled the nearly complete separation of Li and Mn, yielding battery-grade Li2CO3. The incorporation of 2 % H2O2 as an oxidizing agent facilitated the selective precipitation of over 99 % of the manganese in the form of spherical nano-crystalline Mn3O4, while the lithium leaching efficiency remained virtually quantitative. The overall recovery rate for lithium reached 96%, while that for manganese approached 100%. Thermodynamic analysis and comprehensive characterization reveal the underlying mechanisms governing this selective manganese precipitation. Finally, the regenerated LiMn2O4 cathode material synthesized via the closed-loop process exhibited excellent structural integrity and electrochemical performance, confirming the viability and sustainability of the proposed methodology.