Please post examples where you are getting a segfault--the source file and the exact command options you are using to convert it, and what page it happens on. I can fix that for the next release. Are you using v2.42? If a particular page is causing a segfault, you can use the -px option to avoid processing it, e.g. -px 10,20,34-35 will skip pages 10, 20, and 34-35 of the source file.
You need not split the pdf before running k2pdfopt. You can use the -p option to process specific page ranges. There are a number of programs that will join/merge PDFs without extra processing, e.g. cpdf is what I usually use--very fast. I don't know which ones are available for OSX, though.
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