Thank you all.
@Kovid: I tried *.txt -> *.epub -> *.azw3 as you suggested but the problem remained.
@MartinOptic: I tried *.txt -> *.docx (in MS Word) and then *.docx -> *.azw3 (in Calibre) as you suggested but the problem remained.
But I solved the problem as follows:
I highlighted the problem book in the book listing on the Calibre main screen
I clicked on the Edit Book icon in Calibre to open up the Edit utility
I exported the 6Mb part0000.html to another directory, then deleted this file in the Edit utility
Have a quick look at post #1 in this thread, where I wrote:
<li class="calibre3"><span>CHAPTER</span> 12 Hero's Return by Jack Straw</li>
I opened the exported part0000.html in a text editor (Wordpad) and replaced
<li class with <h2 class
and I then replaced
</li> with </h2>
then saved the file and shut down Wordpad.
I returned to tha Calibre Edit utility, imported the altered part0000.html and clicked on the Save icon.
Process complete. This generated the desired ToC.
From this I learnt that sometimes its best to avoid the at times dodgy conversion process in Calibre by using external software.
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